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Battery-Powered 28BYJ-48 Stepper Controller

This project uses one 18650 cell, a TP4056 charger module, an MT3608 boost converter, an Arduino Nano, and a ULN2003 driver board to power a 28BYJ-48 stepper motor.

A DPST switch controls the battery-to-boost path and independently disconnects the motor supply. The Arduino Nano clone used here has no USB VBUS Schottky diode, so the USB and battery-powered 5 V supply must not be connected to the Nano at the same time.

This document describes wiring and power only. It does not include Arduino code.

1. Components

Component Notes
18650 Li-ion cell Single cell, suitable holder or secure battery connection
TP4056 charger module Use a protected module with separate B+, B−, OUT+, and OUT− terminals
MT3608 boost converter Adjustable; set its output to 5.0 V before connecting the loads
DPST on/off switch Both poles operate together
Arduino Nano clone This clone has no VBUS Schottky diode
28BYJ-48 stepper motor Use the 5 V version
ULN2003 driver board Matches the motor’s 5-pin plug
Optional fuse Near TP4056 OUT+; rated above normal load current and below safe limits of the cell, protection board, and wiring
Optional capacitor 100–470 µF across the 5 V rail; observe capacitor polarity and voltage rating

Check the labels on the actual modules: board layouts and terminal names vary. Some TP4056 boards do not have a protection circuit or separate OUT terminals. This diagram requires a protected module with separate load terminals. Do not assume an unprotected TP4056 board provides battery over-discharge or over-current protection, and do not use its B+/B− pads as though they were protected OUT+/OUT− pads.

2. Power flow

18650 ──► TP4056 protected battery/load terminals
                     │
                     └── OUT+ ──► DPST Pole A ──► MT3608 ──► 5 V rail
                                                               ├── Nano 5V
                                                               └── DPST Pole B ──► ULN2003 VCC

The TP4056 is a charger, not a 5 V power supply. Its IN+/IN− terminals are the USB charging input. The B+/B− terminals connect to the battery. The protected module’s OUT+/OUT− terminals provide the battery-voltage load connection.

The MT3608 boosts the cell voltage (approximately 3.0–4.2 V) to 5.0 V.

3. Wiring schematic

Battery:
  18650 (+) ──► TP4056 B+
  18650 (−) ──► TP4056 B−

Charging input:
  USB 5 V (+) ──► TP4056 IN+
  USB GND     ──► TP4056 IN−

Battery-powered load path:
  TP4056 OUT+ ──[optional fuse]──► DPST Pole A common
  DPST Pole A switched terminal ──► MT3608 IN+

  TP4056 OUT− ──► common system GND
  MT3608 IN−   ──► common system GND
  MT3608 OUT−  ──► common system GND
  Nano GND     ──► common system GND
  ULN2003 GND  ──► common system GND

5 V and motor supply:
  MT3608 OUT+ ──► 5 V rail ──┬──► Arduino Nano 5V
                              └──► DPST Pole B common
  DPST Pole B switched terminal ──► ULN2003 VCC

Control and motor:
  Arduino Nano D9  ──► ULN2003 IN1
  Arduino Nano D10 ──► ULN2003 IN2
  Arduino Nano D11 ──► ULN2003 IN3
  Arduino Nano D12 ──► ULN2003 IN4

  28BYJ-48 5-pin plug ──► ULN2003 motor connector

Important TP4056 ground detail

Connect the cell’s negative terminal to B− only. Connect system ground to OUT−. Do not add an external wire directly joining B− to OUT−; that can bypass the protection circuit on a protected TP4056 module.

The battery negative and system ground may be connected internally through the module’s protection circuitry. Use the module’s labeled load terminals for the load.

4. DPST switch operation

The DPST switch has two electrically separate poles operated by the same handle:

  • Pole A: connects TP4056 OUT+ to MT3608 IN+.
  • Pole B: connects the 5 V rail to ULN2003 VCC.
Switch state Pole A Pole B Result
ON Closed Closed Battery powers the MT3608; Nano and motor receive 5 V
OFF Open Open Battery is disconnected from the boost input; motor supply is disconnected

With Pole B open, the motor’s supply is physically disconnected even if the Nano is powered separately. The Nano itself can still be powered by USB when the switch is off.

Pole B disconnects only the ULN2003 VCC; it does not disconnect the driver’s IN1–IN4 signal wires or its ground. If the Nano is powered over USB while Pole B is open, its outputs can still drive the ULN2003 inputs and draw input current. For USB debugging in this state, hold the Nano in reset or disconnect the IN1–IN4 signal wires. The motor supply remains disconnected because ULN2003 VCC is open.

5. MT3608 setup

The MT3608 is adjustable; it is not a fixed 5 V supply.

  1. Turn the DPST switch OFF.
  2. Leave the Nano and ULN2003 disconnected.
  3. Connect the cell and measure MT3608 OUT+ to OUT−.
  4. Adjust the module’s potentiometer until the output is 5.0 V.
  5. Power-cycle and recheck the output.
  6. Connect the Nano and ULN2003 only after confirming the voltage.

The module’s current capability depends on its components, input voltage, and cooling. The MT3608 IC’s “2 A” switch-current rating does not mean every module can deliver 2 A at 5 V.

6. Operating modes

Run from battery

  • DPST: ON
  • Nano USB: unplugged
  • TP4056 charging USB: unplugged

The Nano and motor are powered from the MT3608’s 5 V output.

Charge the battery

  • DPST: OFF
  • TP4056 USB input: connected to a 5 V charger
  • Nano USB: unplugged

With Pole A open, the battery-powered load path is disconnected. Keep the Nano USB unplugged during charging as the conservative procedure.

Debug over USB serial

  • DPST: OFF
  • TP4056 charging USB: unplugged
  • Nano USB: connected to the computer
  • Disconnect the MT3608 OUT+ wire from the 5 V rail while debugging.

The Nano clone has no VBUS Schottky diode. Disconnecting the boost output during USB debugging avoids applying USB 5 V to the MT3608 output. Pole B remains open, so the ULN2003 motor supply is isolated.

Never connect Nano USB while the DPST is ON. In that state, the MT3608 supplies the Nano’s 5 V pin, which could back-feed the computer’s USB port.

With the DPST OFF during USB debugging, the signal pins remain connected to ULN2003 IN1–IN4; hold the Nano in reset or disconnect those wires, as described above.

7. First power-on checklist

  1. Confirm the cell goes to TP4056 B+ and B−.
  2. Confirm the circuit ground goes to TP4056 OUT−; do not bridge B− to OUT−.
  3. With the switch OFF and loads disconnected, set the MT3608 output to 5.0 V.
  4. Recheck polarity and wiring.
  5. Connect the Nano and ULN2003.
  6. Run from battery only with the switch ON and Nano USB unplugged.

8. Design notes

  • Use the Nano’s 5V pin for the regulated 5 V rail. Do not use VIN for this 5 V supply.
  • The 28BYJ-48 plugs directly into the ULN2003 board; individual coil wires should not need to be jumpered.
  • Standard 28BYJ-48 ULN2003 boards do not have a current-adjustment trimmer. Leave their bypass capacitors installed.
  • An optional 100–470 µF capacitor can be placed across the 5 V rail and GND near the loads to help with supply dips. Observe its polarity.
  • Keep the Nano, MT3608, and ULN2003 grounds connected to the TP4056 OUT−-referenced system ground.
  • Pole B isolates the ULN2003 motor supply only. It does not isolate the control inputs or ground, so it is not a complete electrical disconnection of the driver board.
  • Do not charge and run the load simultaneously with this simple TP4056 arrangement. Supporting that requires a proper power-path/load-sharing design.

9. References

These tutorials cover the stepper/driver portion of the project:

TP4056 load-sharing background:

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