MintyBoost USB Charger Kit v3.0
Contents
1. SF as bs 3 ome is A my a SO 2 ee ao Next solder in the 2xAA battery holder The red wire goes to the hole marked and the black wire goes to the hole marked Make sure you have them in right or you can damage the circuit Solder in the wires If they re a little long you can clip them Make Projects www makeprojects com Page 10 of 18 MintyBoost USB Charger Kit v3 0 Step 10 Insert the boost converter IC 9 2 LT1302 CN8 5 y AN Finally carefully insert the boost converter chip Make sure the notch in the chip matches the notch in the socket f you soldered your socket backwards make sure the notch faces the flat edge of the PCB as shown Make sure the chip is seated all the way in and that the pins aren t bent Make Projects www makeprojects com Page 11 of 18 MintyBoost USB Charger Kit v3 0 Step 11 Time to test voltages Clean up your workbench so there are no little wire pieces that can short the kit it s also just nice to have a clean desk We like to put down a piece of paper to ensure there s no chance of damage Then insert 2 fresh AA batteries alkaline or rechargeable is OK Wait a few seconds and feel the battery and chip Are they getting hot If so remove the batteries and look over your work The kit should not even get warm Use your multimeter to measure the voltage between the 2 outer pins of the USB connector Read2. oe 6 A Cl ie Next you ll solder the 75K 1 resistors R2 and R4 These are blue with the following stripe colors violet green black red brown These resistors are very small and easy to confuse with the other blue resistors but the others have white and yellow stripes so make sure these don t These resistors are used by Apple iPhones and such to determine what kind of charger is connected Solder the resistors as you did the first one one point at a time checking your work Clip the long ends Step 4 Solder resistors R1 and R3 The 2 remaining resistors are 49 9K 1 resistors and have yellow white white red brown Stripes They go into slots R1 and R3 Solder them in and clip the leads so they re nice and tidy Make Projects www makeprojects com Page 5 of 18 MintyBoost USB Charger Kit v3 0 Step 5 Add the ceramic capacitors The ceramic capacitors C1 and C2 are symmetric nonpolarized so they can go in either way Place them so their 2 legs leads slide through the 2 holes in the PCB pads and the capacitor sits flat against the PCB C1 helps stabilize the output voltage and filters out high frequency noise so the 5V output is nice and smooth C2 is used to stabilize the internal reference of the boost converter chip This keeps the chip stable so it will generate a precise voltage Ignore that black and white diode in the photo d
3. that it s upside down later when it s time to install the chip The socket has short legs so it can be annoying to keep in the right position Hold it in place with one finger and tack solder a corner Once that s done solder in the remaining 7 pins There s no need to clip Make Projects www makeprojects com Page 8 of 18 MintyBoost USB Charger Kit v3 0 Step 8 Solder the power inductor and capacitors The power inductor L1 is used by the DC DC converter chip to store and convert power from low voltages to high Inductors are just a coil of wire so they have no polarity and can be placed either way The inductor may not sit perfectly flat since the socket is in the way a bit That s OK Just lean it over a little Solder in both leads and clip them short Next are the 2 electrolytic capacitors C3 and C4 These are are commonly used for low frequency noise often paired with a ceramic capacitor Here they help smooth both the input and output voltages to keep them stable during the up conversion Electrolytic capacitors are polarized and must be placed correctly or the circuit will not work The longer positive lead must go into the pad marked with a as shown Solder in the 2 capacitors then clip the wires Make Projects www makeprojects com Page 9 of 18 MintyBoost USB Charger Kit v3 0 Step 9 Solder the battery holder ST Fn Aane 08885 2 a Et C5 AF To
4. to the MintyBoost It will go right in the middle of the printed circuit board PCB over the silkscreened text that says R5 Resistors are non polar which means they don t have a direction you don t have to worry about putting it in backward because they work the same either way Bend the resistor leads down into the shape of a staple and slip it into the holes in the top of the PCB Bend the little leads outward so that you can flip over the PCB and the resistor will stay in place Now you ll solder Place the flat of the soldering iron tip against the silver ring pad and one of the wires leads of the resistor at the same time for 2 seconds This will heat them both up to 600 F 700 F Then poke the end of the solder in there so that it flows into the hole and forms a solder joint Solder joints should be smooth and shiny and fill the entire pad wicking up to the lead You shouldn t be able to wiggle the wire and have it move in the hole Once you re happy with your first solder joint solder the second resistor lead Now use your diagonal cutters to clip the excess wire just above the end of the solder joint There should be almost no wire left sticking out Make Projects www makeprojects com Page 4 of 18 MintyBoost USB Charger Kit v3 0 Step 3 Solder resistors R2 and R4 e 2 t Ve ow Tits of a _ j ar a r P 5 d GD fo T ep sce S iV Se 9 oe e ie
5. 3 0 SUMMARY This kit makes a small and simple but very powerful USB charger for your MP3 player camera cellphone and just about any other gadget you can plug into a USB port to charge See the user s manual for compatibility tests The charger circuitry and two AA batteries fit into an Altoids gum tin and will run your iPod for hours in fact for 2 5 times longer than you d get from a 9V USB charger You can use rechargable batteries too The secret is in the high efficiency power conversion circuit it s up to 83 effective so from your two AA batteries you get 2 5 times more power than you d get from a 9V battery The MintyBoost Kit Version 3 was designed in NYC by open source hardware pioneer Adafruit Industries in partnership with MAKE and Maker Shed It outputs 5V 500mA and it now works with iPhones and newer iGadgets You can use any AA batteries or even upgrade to C or D cells for a mega battery pack In tests the MintyBoost 3 0 gave the following results iPhone all types 3 4 full recharge iPod video tested using alkaline batteries 3hrs more video 1 full recharge iPod mini tested w rechargables 26hrs more 1 5 full recharges iPod nano 4 full recharges iPod shuffle 60 hours more 5 full recharges This kit is suitable for beginners Basic soldering is necessary but even if you ve never soldered before it s pretty easy And the design is open source so you can etch your own circuit bo
6. Adafruit s voltage tutorial here You should get a bit higher than 5 0V but lower than 5 2V If you get much higher than 5V first check that your multimeter has a fresh battery Really This is a really common problem If you get lower than 3V remove the MintyBoost batteries and check your work Next check between the rightmost pin and the second and third pin These should both be at just about 2 0V Once you re happy with these tests remove the batteries from your kit and finish assembling the kit Make Projects www makeprojects com Page 12 of 18 MintyBoost USB Charger Kit v3 0 Step 12 Solder the USB type A connector Next is the USB type A connector This is the same connector that s on a computer and nearly all USB charging cables will plug into it The connector should snap easily into place The 2 large side connectors are used for mechanical strength They keep the connector attached solidly to the PCB so make sure to use lots of solder or it will break off from use The 4 middle pins carry the power and data for USB Solder in all 4 Make Projects www makeprojects com Page 13 of 18 MintyBoost USB Charger Kit v3 0 Step 13 Test and troubleshoot of y LA ne a y gi ja 5 Lf R bai jm p a Ae 478206 Make Projects hee PB EF www makeprojects com Now is a good time to test your kit before you put it in the case Check that it charges your fav
7. MintyBoost USB Charger Kit v3 0 Make Projects b uild hack tweak share discover MintyBoost USB Charger Kit TOOLS Desoldering tool optional 1 if you re prone to incorrectly soldering parts Flush diagonal cutters 1 for cutting leads close to the PCB Multimeter or oscilloscope optional heck voltages and continuity Solder rosin core 60 40 1 Use good quality solder bad solder causes bridging and cold solder joints Get at least a od spool so you won t run out soldering iron with temperature control 1 One with a stand is best Don t use a ColdHeat soldering iron they re not suitable for delicate electronics work and can damage the kit Third hand tool with magnifying glass optional 1 makes things go much much faster Tinsnips 1 Make Projects www makeprojects com PARTS MintyBoost USB Charger Kit v3 0 1 Includes all of the following parts Boost converter 1 LT1302CN8 5 socket 1 Capacitors electrolytic 2 for power supply Capacitors ceramic 2 for bypass Resistor 1 8BW 5 3 3K R5 1 color coded orange orange red gold resistors 2 violet green black red brown resistors 2 vellow white white red brown Diode Schottky D1 1 1N5818 or 1N5817 etc Power inductor 1 at least 1A current capability USB jack 1 Battery holder 2xAA 1 MintyBoost printed circuit board PCB 1 Page 1 of 18 MintyBoost USB Charger Kit v
8. ard breadboard the circuit or simply buy the kit from the Maker Shed Make Projects www makeprojects com Page 2 of 18 MintyBoost USB Charger Kit v3 0 Step 1 Gather your tools and parts 3V battery LT1302 Check the tools and parts lists to verify you have all the parts necessary to make the kit Most importantly confirm which version of the kit you have Look at the packaging and the PCB find that v3 that s on the back near the top Place the PCB in a vise and turn on your soldering iron f you don t know how to solder check out this excellent tutorial page Here s the schematic diagram that explains the circuit you ll solder But don t worry you don t need to know how to read it the following instructions will tell you all you need to know to solder it Make Projects www makeprojects com Page 3 of 18 MintyBoost USB Charger Kit v3 0 Step 2 Solder resistor R5 fa hy ca xi amp 7 y E E a a WT s i teal ee7e os rd pn eg ao mE 2 p a en i a bi ja m ka ak D ell a ET i ljg F ae E o J M ym Cis You re looking for a small oval tan thing with two wires leads and colored stripes In the case of resistor R5 the stripes are orange orange red which indicates a 3 3K resistor This resistor is used to improve the high current capability of the boost converter chip and is a new addition
9. it in case other people interested in designing and making kits are interested in learning how to start selling their own kits This document was last generated on 2013 01 15 03 24 38 PM Make Projects www makeprojects com Page 18 of 18
10. on t place that yet just the two yellow blobbies Solder and clip the 2 ceramic caps Make Projects www makeprojects com Page 6 of 18 MintyBoost USB Charger Kit v3 0 Step 6 Solder the Schottky diode The Schottky diode D1 is part of the boost converter Essentially it is used to make Sure energy is transferred in only one direction from the batteries to the USB port Diodes have a special property that current can only pass through them in one direction so it s important to make sure they re not inserted backwards Examine the diode and find the end with a white stripe This stripe should match up with the silkscreened image which also has a stripe on one end In this image it is toward the top Solder and clip the diode Lookin good Make sure there are no shorted wires or dirty solder joints Make Projects www makeprojects com Page 7 of 18 MintyBoost USB Charger Kit v3 0 Step 7 Solder the IC socket The IC socket protects the chip and allows you to replace it if there are any problems Place the socket right over the 3 3K resistor The resistor shouldn t interfere as long as it was soldered in properly Make sure you place the socket so that the notch in its edge matches up with the notch in the silkscreened image In this image it s near the bottom If you mess this up don t try to desolder the socket instead just keep going and remember
11. orite gadget and perhaps wait a few minutes to make sure the battery meter inches up If you re having trouble getting the device to recognize the MintyBoost as a charger it could be because it only wants USB spec chargers This is easy to do with the MintyBoost and always worth a shot as it will get most stuff up and running Here s how Remove the batteries from your kit Use your soldering iron to heat up the 2 middle USB pins at the same time and blob on a bunch of solder to short them together Now try again Page 140f18 MintyBoost USB Charger Kit v3 0 Step 14 Prepare the case OK now you re ready to put it in the case You could buy a tin of Altoids gum but our kit includes a tin that fits perfectly You ll need the MintyBoost kit the empty tin the 2 pieces of double sided adhesive foam tape and a pair of tinsnips Cut 2 notches in one end of the tin the short side just about where the flat part ends and the tin starts to round out Step 15 Now you want to bend the flap back and forth to break it off If you re careful you can bend it in more than out which will make it round into the tin one less sharp edge Make Projects www makeprojects com Page 150f 18 MintyBoost USB Charger Kit v3 0 Step 16 Try a test fit Remove the kit batteries Slide the board in first then fit the battery pack in Don t put the batteries in for thi
12. s test The circuit board could short against the tin and destroy the circuit Make sure the lid closes well the USB connector fits well and the notch is deep enough so the jack doesn t interfere with the hinged lid Make Projects www makeprojects com Page 16 of 18 MintyBoost USB Charger Kit v3 0 Step 17 Assemble everything in the case Once you re happy with the fit remove the electronics and put the double sided sticky foam tape on both the circuit board and the battery holder IMPORTANT Make sure no pins or parts or leads are sticking out and can touch the tin f necessary use more foam duct or electrical tape to protect the circuit Clip your leads short so they don t poke through the foam You can easily destroy the circuit by being sloppy here Fit the circuit board in first and make sure it sits all the way to the end it s a tight fit Make Projects www makeprojects com Page 17 of 18 MintyBoost USB Charger Kit v3 0 Step 18 Boost away SEES NUP ALU i 2 PALORIE FOOD PA EnA TA SUGARY if ae ry 1 NS ba An d ARTIFICIALLY FLAVORED PERMINT You re done Plug in your favorite gadget s USB charging cable and boost away Remember that because the MAX756 chip uses virtually no power you don t have to remove the batteries to turn off the Minty Boost Just plug and unplug devices whenever you want Adafruit has also documented the process of designing this k
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