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Battery Low Indicator

OVERVIEW
The purpose of the Battery Low Indicator is to give a visual indication when a battery has been discharged below a specific level. This is especially crucial for re-chargeable batteries that should not be discharged below a certain voltage level. This lower voltage limit depends upon the ducing accurate time delays or oscillations (pulses). The NE555 usually operates in two modes- mono-stable mode (for producing a single pulse when triggered) and the astable mode Fig. 3: Pin-out of a NE555 Timer IC (for generating pulses or oscillations, with the desired duty cycle). The threshold (Pin6) and trigger (Pin2) level for the NE555 are normally two-thirds and one-third, respectively, of VCC. However, connecting the trigger input to the threshold input causes the NE555 to run as a multi-vibrator. This is known as the astable mode of operation whereby pulses or oscillations are generated, the frequency and duty cycle of which can be controlled independently with two external resistors and a single external capacitor. The Battery Low Indicator uses the reset function of the NE555 to implement the visual indication mechanism. The reset pin of NE555 is active low i.e. when the voltage on this pin falls below 0.7V (approximately) it makes the output low too (0V), overriding all the other inputs. However, when the reset pin is held high in the astable mode, the output (pin3) of the NE555 becomes high and oscillations are generated at this pin which can be used to drive loudspeakers, motors, piezoelectric transducers, LEDs, etc. Zener Diode (for Voltage Reference): A Zener diode permits current not only in the forward direction (like a normal diode) but also in the reverse direction, if the voltage is larger than the breakdown voltage known as Zener knee voltage or Zener voltage. Reverse-biased Zener diode will exhibit a controlled breakdown and allow the current to keep the voltage across the Zener diode at the Zener voltage. For example, a diode with a Zener breakdown voltage of 3.2 V will exhibit a voltage drop of 3.2 V if reverse bias voltage applied across it is more than its Zener voltage. The Zener diode is therefore ideal for applications such as Fig. 4: Orientation the generation of a reference voltage and Representation of or as a voltage stabilizer for low-curZener Diode rent applications. When connected in parallel with a variable voltage source so that it is reverse biased, a Zener diode conducts when the voltage reaches the diodes reverse breakdown voltage. From that point on, the relatively low impedance of the diode keeps the voltage across the diode at that value.
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Fig. 1: Block diagram of the Battery Low Indicator

type of the battery. The Battery Low Indicator circuit can be typically used for 12V batteries to give an indication of the battery voltage falling below the pre-set value. The indication is in the form of a flickering LED.

COMPONENT DESCRIPTION
Dual Comparator IC LM319: The LM319 is a precision high-speed dual comparator fabricated on a single monolithic chip. It is designed to operate over a wide range of supply voltages down to a single 5 V logic supply and ground. Although designed primarily for applications requiring operation from digital logic supplies, the LM319 series are fully specified for power supplies up to 15 V. Of its two indeFig. 2: Pin-Out of the Dual Comparator pendent comparators, IC LM319 the Battery Low Indicator uses only one for comparing the battery voltage to the reference voltage. The comparator being used in the circuit accepts inputs from pin4 (non-inverting) and pin5 (inverting) while the corresponding output is generated at pin12. This comparator output (at pin12) is responsible for holding the reset pin of the NE555 timer IC either high or low, depending upon which the NE555 may or may not run as a multi-vibrator. Single Timer IC NE555: The NE555 is a precision timing circuit capable of pro-

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5V Voltage Regulator IC 7805: The 7805 is a three-terminal positive regulator with a fixed output voltage of 5V. The 7805 employs internal current limiting, thermal shut down and safe operating area protection, making it essentially indestructible. If adequate heat sinking is provided, they can deliver over 1A output current. In the Battery Low Indicator circuit, both IC1 (dual comparator LM319) and IC2 (NE555 timer) operate off regulated +5V DC Fig. 5: Pingenerated by voltage regulator IC 7805 (IC3).
out of 7805 Voltage Regulator

Resistors (R1-R8)

Zener Diode (D1) Printed Circuit Board (PCB) IC Sockets

IC1 Comparator

IC2 Timer

Capacitors (C5, C7)

Red LED

Single-pole double-throw (SPDT) toggle switch: A SPDT toggle switch may be used as a simple on-off switch by connecting the COM terminal and either of the A or B terminals shown in the diagram. The terminals A and B are interchangeable, so switches are usually not labeled. The terminal which is connected in the circuitry comes to be known as the on position Fig. 6: SPDT Toggle of the toggle switch. Switch Notations Resistors: The most basic role of resistors is current limiting i.e. precisely controlling the quantity of electrical current that is going to flow through a device or a conductor. Resistors can also be used as voltage divider, in other words they can be used to generate any voltage from an initial bigger voltage by dividing it. They are also used as pull-up resistors in electronic logic circuits to ensure that inputs to logic systems settle at expected logic levels if external devices are disconnected or high-impedance. They may also be used at the interface between two different types of logic devices, possibly operating at different power supply voltages. Capacitors: Capacitors store electric charge. They are used with resistors in timing circuits because it takes time for a capacitor to fill with charge. Capacitors are also used to smooth varying DC supplies by acting as a reservoir of charge. They are also used in filter circuits because capacitors easily pass AC (changing) signals but they block DC (constant) signals. Note: Electrolytic capacitors are polarized and they must be connected the correct way round, at least one of their leads will be marked + or -. They are not damaged by heat when soldering.

Voltage Regulator (IC3)

SPDT Toggle Switch (S1)

Ceramic Capacitors (C2, C3, C4, C1 and C5)

Preset (VR1)

Component Identification

SPDT Toggle (On/Off Switch) Connections to battery under test

Completed prototype after assembling the components and soldering

WORKING PRINCIPLE
The heart of the Battery Low Indicator circuit is the dual comparator IC LM319 (denoted as IC1 here) which compares the batterys voltage to a reference voltage level. Only one of the two independent comparators that are a

part of the LM319 is used in the circuit. The two inputs to this comparator are: 1. Reference voltage which is applied to the noninverting input pin (4). It is held constant at approximately 1.2V by the Zener diode D1. 2. Batterys voltage which is applied via a potential divider arrangement built around resistors R2, R3 and preset VR1 and fed to the inverting input pin (5). The corresponding output is generated at pin12 of IC1. Pre-set VR1 is very important as it sets the voltage level at which a visual indication of the low battery level is generated. For example: If the battery under test is of 12V and an indication is required as soon as the battery voltage falls below 10.5V, the voltage at the inverting input (pin5 of IC1) should be adjusted to 1.2V using preset VR1. Initially, when the battery is fully charged, the voltage at the inverting input (pin5) of IC1 is higher than the non-inverting input (pin4- voltage level held constant at approximately 1.2V by D1). This causes the output at pin 12 of IC1 to remain low. The reset pin (pin4) of NE555 timer
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(IC2) is connected to the output pin of IC1 and hence, a low gets applied to it correspondingly. Since the reset pin is active low, the NE555 is reset continuously and oscillations are not generated at its output (pin3). As a result, LED1 does not start blinking. Considering the example values, when the battery voltage falls below 10.5V, the voltage at the inverting input (pin4) of IC1 becomes lower than the non-inverting input (pin5) and the output at pin12 of IC1 goes high. This applies a high to the connected reset pin of IC2 (NE555 timer) and the astable multi-vibrator built around IC2 starts generating oscillations. LED1 is connected to the output pin (pin3) of IC2 and hence blinks to indicate that the battery voltage is low and that the battery needs to be charged before further use. the joint still. After all the components have Semiconductors: been soldered, check the soldering IC1 - LM319 Dual Comparator IC2 - NE555 Multi-vibrator/Timer closely for any breaks. Inspect your IC3 - 7805 DC Voltage Regulator work carefully under a bright light. The D1 - 2.2V Zener Diode solder joints should have a shiny look LED1 - Red LED about them. Check that there are no Resistors (all -watt, 5% carbon unless solder bridges between adjacent pads. stated otherwise): Connectivity in circuit can be tested by R1 - 470 kilo-ohm R2, R5, R7 - 100 kilo-ohm the help of a multi-meter Parts List
R3 R4, R6 R8 VR1 10 kilo-ohm 1 kilo-ohm 470 ohm 10 kilo-ohm Preset

Precautions to be taken: Please note the connection of Capacitors: jumper wires on the PCB. These are C1, C6 - 0.01F, Ceramic Disk denoted on the PCB with the letter J C2, C3, C4 - 0.1F, Ceramic Disk along straight lines indicating the drills C5, C7 - 1F, 10V electrolytic where they are to be soldered. Miscellaneous: S1- SPDT Toggle (On/Off) Switch It is preferable to use multiPrinted Circuit Board (PCB) thread wires for the jumper links, rather than single thread copper wires since they tend to break upon soldering. Please note that the footprint of the SPDT toggle ASSEMBLING THE KIT switch does not match the drills provided on the PCB. This Preparing the soldering iron: is because such components are connected using wires and Place the soldering iron in its stand and plug in. only some of all the pins/legs of the relay/switch are to be The iron will take a few minutes to reach its operating temsoldered onto the PCB. Please refer to the previous compoperature of about 400C. nent description to figure out these connections. Dampen the sponge in the stand. Pay attention to the polarity of components like Wait a few minutes for the soldering iron to warm diodes and electrolytic capacitors before soldering. The pins of the IC sockets may have to be adjusted up. You can check if it is ready by trying to melt a little solder on the tip. and bent in order to insert them into the drill-holes prior to Wipe the tip of the iron on the damp sponge. This soldering. The IC sockets and not the IC itself are soldered will clean the tip. Melt a little solder on the tip of the iron. onto the PCB for easy testing and debugging. IC holders/sockets should be soldered with the Soldering the components: notch at the correct end. Use the component overlay on the PCB to insert PRE-TEST the components and solder them in the following order: 1. Resistors Do not insert the ICs into their sockets yet. First, note 2. Capacitors the polarity of the battery under test (also take note that 3. Zener Diode and LED the battery low indicator cannot be used for batteries with 4. Jumper Links output voltage greater than 14V). Next, connect this battery 5. IC Sockets under test to the circuit and measure the voltage across pin8 6. Variable Resistor (Pre-set) (+V cc) and pin1 (GND) on the socket of IC2 i.e. the NE555 7. Voltage Regulator IC timer. It should read approximately 5V. Similarly the volt8. SPDT Toggle Switch age across pin11 (+V cc) and pin3 (GND) of IC1 (comparator Hold the soldering iron like a pen, near the base LM319) should also be 5V. If these readings are ok then reof the handle. Touch the soldering iron onto the joint to be move the battery and insert the ICs. Take care to not to bend made. Make sure it touches both the component lead and any of the IC pins while doing so. Accidentally applying a the track. voltage to the circuit that is greater than the bearable limit Hold the tip there for a few seconds and feed a can burn the ICs or some other sensitive component. little solder onto the joint. It should flow smoothly onto the TESTING lead and track to form a volcano shape. Apply the solder to the joint, not the iron. Connect the battery once again so as to apply the Remove the solder, then the iron, while keeping battery voltage to the circuit.
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It is preferable to begin troubleshooting process from output stage onwards and then proceed to the input side. To begin, apply a high (5V) to reset pin4 of the NE555 timer. Since the reset pin is active low, this should cause the output at pin3 to oscillate and the LED should start blinking. If this mechanism is working as described then the circuit stages beyond IC2 are working fine. If not then proceed with the next step. Next, check for the voltage change at pin 12 of IC1. When Vpin4 < Vpin5 of IC1, the output should be low (approx. 0.34V). On the other hand, when Vpin4> Vpin5 the output voltage should be high (approx. 4.95V). If this kind of switching between voltage levels is taking place then your IC is working. If voltage changes do not take place then there may be problem in the IC. If the IC appears to have heated then replace it. Check the soldering for any shorting points. Check the polarity and connection of components like diodes and capacitors. Also, verify whether all the resistances being used are of the required value. Make sure that you have the right components in the right place. Further, remove the IC from the IC socket and check that no IC pins are bent up under the body of the ICs. This can sometimes happen when inserting ICs into sockets. Once the circuit problem has been resolved your Battery Low Indicator is ready to be installed and used.

Fig. 7: Circuit Diagram of the Battery Low Indicator

To perform a test on the battery low indication mechanism, the circuit first needs to be calibrated so as to set a voltage value at which it would indicate a low battery through the blinking LED. Connect a supply voltage between 4 to 14V at which you want the battery low indication. For example this value is 9V. After the circuit has been powered, check the voltage at pin4 (non-inverting input) of IC1. This should be approximately 1.2 Volts. Next, check the voltage at pin5 (inverting input) of IC1. This will usually be more than the voltage at pin4. In this condition, the output pin (pin12) of IC1 is held low at approximately 0.34V and the LED is not glowing/blinking. While monitoring the voltage at pin5, rotate the preset and note the voltage drop at this pin. As soon as the voltage at pin5 falls below that at pin4 (approximately 1.2V), the LED will start to blink and the voltage at output pin12 will go high. This output voltage level should approximately be equal to 4.95 Volts. Leave the preset setting at this position. Now, the circuit has been calibrated to indicate a battery low if its voltage falls below 9V. Check by applying a battery of less than 9V output. The LED should blink. The circuit can be calibrated for any value between 414V by following the above procedure.

TRY THIS OUT NEXT!

The Battery Low Indicator implemented here provides a mechanism for visual indication only. The circuit can be easily modified to include a piezoelectric buzzer to give audible indication every time the battery voltage falls below the set-level. Further, the voltage range can be increased by incorporating a different Zener diode (with a greater breakdown voltage) and a large preset in place of VR1.

CONTACT DETAILS
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Documented by Aditi Goswami

TROUBLESHOOTING
If the circuit is not working as desired then proceed as below:

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