Easy way to repair broken automatic passthroughs?

[ferv0r]

I have several USB automatic passthroughs that no longer work, probably because juice leaked into the activation switch.

Is there an easy way to fix it?

How difficult would it be to rip it open and turn it into a manual?

I've never done any electrical work before, but I am an engineer, so hopefully I should be able to figure things out once I get started.

 

[breakfastchef]

That is your best option. Tear out the guts (PCB, LED, capacitor) and turn it into a straight manual passthrough. An unused USB cable laying around the house is a good upgrade to the OEM wire. Drill a hole in the tube for a switch. Mounting the switch is probably the most frustrating part of the project.

Momentary/tactile switches will get annoying. Most folks run to Radio Shack and get the tiny tactile switches. They work, but not for very long, so you will be redoing the PT fairly regularly. When it works, it is great; when the button fails, it is a PIA. If you do not care what the device looks like, you can use 1/2" copper tubing and 1/2" endcaps to fashion a solid PT with a higer rated and larger momentary button, also from Radio Shack.

 

[mnealtx]

IF you can get at the switch, you should be able to clean it. Otherwise, you could wire in a normally open momentary switch and go to a direct wire connection to the atomizer connector.

Going that route, it's probably best to use a wall-wart (plug in USB power supply) rather than computer USB - you want to make sure you get a full amp to the atomizer, and not all computer USB can supply that.

 

[500KV]

There are probably a thousand ways to build a passthrough.
I built one using a 2xAAA box and one using a 2XAA box, both from RS.
Straight passthrough, manual switch, no battery, and use them with a Kensington Power-pack.
Nothing could be simpler.

 

[breakfastchef]

There are probably a thousand ways to build a passthrough.
I built one using a 2xAAA box and one using a 2XAA box, both from RS.
Straight passthrough, manual switch, no battery, and use them with a Kensington Power-pack.
Nothing could be simpler.

What I like about your solution is you can use a better switch and it can easily be replaced.

 

[500KV]

What I like about your solution is you can use a better switch and it can easily be replaced.

It really does simplify things.
I finally gave up on the miniature switches and now use those rated 1.5 and 3 amps.
Not as pretty but much more reliable.

 

[ferv0r]

Okay, I was hoping that people figured out an easy way to fix these cheap automatic switch passthroughs. Oh well.

I understand the general idea for converting to a manual passthrough. I just need to create a circuit, the switch to close it, a power source (USB), and the adapter for the atomizer. As long as I can figure out which wire is which, that shouldn't be hard (once I learn how to use a soldering iron, hah). I'd want to seal the thing while I'm at it, so I don't trash it again.

By the way, why are the small manual switches failing? It's seems like such a simple component. Are they failing because the wires/connections are so tiny that the power from the USB is burning them out? That's weak.

 

[mnealtx]

That's weak.

That's exactly why they fail...

 

[breakfastchef]

Most USB cable use red and black for the power. Black directly to the threads and red to switch ond onto the center conductor (vice verso if you prefer). Think light bulb light switch.

 

[500KV]

By the way, why are the small manual switches failing? It's seems like such a simple component. Are they failing because the wires/connections are so tiny that the power from the USB is burning them out? That's weak.

The smaller switches are generally rated at 50Ma.
Your atomizer is drawing ~1.5 amps at 5 volts.
They are simply being overloaded.

 

[four2109]

So, what is the lifespan fo the smaller switches on 3.7- 4.1 volts?
Just curious. I just like the size, and a 14500 battery will last me all day.

 

[mnealtx]

So, what is the lifespan fo the smaller switches on 3.7- 4.1 volts?
Just curious. I just like the size, and a 14500 battery will last me all day.

It might last 5000 activations, and it might last 5 - it's literally a crapshoot every time you hit the switch.

It's like using a piece of clothesline as a tow rope - it might work for a while, but sooner or later.....pop!!!