Here are a few photos of the contents of an
iLuv i601 external
battery pack intended for a first generation Apple iPod Nano.
This is an interesting device as within its very slender
enclosure it contains: -
a li-poly (lithium polymer) battery with a few hundred mAh of
integrated charging and protection circuit for above,
5V regulated boost converter circuit with output drive
capability of a few hundred mA.
This array of functions makes it an ideal donor for little
projects which need a nicely regulated uninterruptable power
supply, e.g. a digital alarm clock.
The battery comes as part of a kit which includes a handy
multi input voltage mains adaptor with a regulated 5V 2A DC output
via a standard USB type A connector. This will undoubtably come in
handy for other things, especially charging other USB equipped
stuff while traveling.
I got mine for a bargain £5.00 at my local branch
TK Maxx. (It didn't fit the iPod I
bought it for as the connector is positioned to suit only the
first generation iPod Nanos. I didn't notice if this was mentioned
on the outer packaging, but that's probably why they are cheap.)
Being so compact, this was unsuprisingly a bit of a bugger to
get into. The white plastic case is welded shut at the seams and
the delicate foil body of the li-poly battery is fixed to both
halves with extremely tenacious sticky foam pads.
I tackled it by cracking the lower edge of the seam with a
small flat blade screwdriver and working a little way around the
corners up the body, but stopping once I could see the location of
the battery. Putting a screwdriver through the soft foil of the
lithium cell would be a sure way to cause unpleasantness such as
hot gasses escaping or small exlopsions.
I managed to get the back off by running some alchohol down the
inside of the case. I use whiteboard cleaner as there's a ready
supply of it in the office stationary cupboard. I found the sticky
residue isn't really dissolved by this stuff but it is enough to
loosen the foam pad it adheres to.
After a few minutes softening, the back can gently be prised
off the battery by inserting a soft and wide plastic blade (e.g.
a credit card) in the gap.
Inside, the charging and output PSU circuits are all contained
on a single PCB, which helpfully has "In", "Out" and "GND" marked
in the silkscreen. Almost made for hacking!
I actually went a little further and removed the battery from
the other half of the case. I wouldn't recommend it as the
operation is quite precarious and isn't necessary unless the bulge
at the end makes the unit too large to fit your project's
enclosure, or if having redundant hardware really bothers you.
Underneath the main board are a couple of little PCBs with the
audio circuitry and connectors on. These are joined to the main
PCB via wires soldered to the three pads marked as described above
on the reverse of the PCB.
Reuse as a Project Power Supply
The PSU output is quite smart in that it appears to need to see
a load before it is enabled. This load can apparently be as small
as 1mA (I didn't try any less).
The output it latched into either on or off state, depending on
whether the load was present while the input voltage was present.
Therefore if this is being used for an uninterruptable supply for
some TTL logic or a microcontroller, the PSU would just always
be powered up until the battery runs flat.
I guess as per the iPod itself, the input needs to be a
regulated 5V. When the input supply is present, the output voltage
seems to match the input.
(Whilst charging, an onboard bicolour LED illuminates red. It
turns green once the bettery is fully charged.)
With a small load (such as a 4K7 resistor), the output will
go to 5V once the input supply is removed.
It appears that once latched on, the load can be removed
completely and the PSU stays on indefinitely (until the battery
This site comprises a collection of pages poorly documenting some of the projects I've taken on. If you find anything here useful or inspirational, feel free to copy or use as the basis for your own project.
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