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Breaktru Forum  |  eCigarette Forum  |  Modding  |  Topic: Low Battery Indicator
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Author Topic: Low Battery Indicator  (Read 46328 times)

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Online Breaktru

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Low Battery Indicator
« on: May 14, 2013, 06:34:49 PM »
I used the schematic from Electronics-DIY.com and revised it for one LED and for two 3.7 cells. Will indicate at 6.0v.
Use 1% resistors. 1/8 watts is fine. The components can be wired tightly together as shown in the Elect. DIY photo except there will be one LED not two and one more resistor.
See the attached photo (only viewable to logged on members).

I have it also revised it for a single 3.7v cell and low voltage indicates at 3.0v but need to tweak it for a brighter LED illumination.
It's not as easy as I thought. Changing the resistor for the LED will also effect the Adjustable precision shunt regulator (TL431) from turning on. The Ref pin requires 2.5v to turn on.

The attached schematics show an ON-Semi diode. Pin numbers vary on manufacture so check your manufactures datasheet.
See --> DETAILS

**I am happy to share info with all that drop by this forum. So dropping a mention when you post your mod elsewhere would be a decent gesture.
Show your support by signing up as a member and please participate by posting**
« Last Edit: May 09, 2014, 06:12:46 PM by Breaktru »

Online Breaktru

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Re: Low Battery Indicator
« Reply #1 on: May 15, 2013, 12:51:12 PM »
Okay, I've got this circuit revised for a single 3.7v cell note the resistor changes. All resistors are 1% tolerance.
« Last Edit: May 15, 2013, 09:15:56 PM by Breaktru »

Offline Tameron

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Re: Low Battery Indicator
« Reply #2 on: May 16, 2013, 09:17:36 AM »
Very good  :thankyou:
This looks small enough to squeeze in to any small mod project  :yes"

Online FlameOut

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Re: Low Battery Indicator
« Reply #3 on: May 16, 2013, 09:39:03 AM »
I'm going to build two. One for my 3.7v mod and one for my 7.4v mod.
Question. Is the TL431 the same as the LT431?

Online Breaktru

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Re: Low Battery Indicator
« Reply #4 on: May 16, 2013, 10:29:25 AM »
I'm going to build two. One for my 3.7v mod and one for my 7.4v mod.
Question. Is the TL431 the same as the LT431?


The pins and Ref voltage are the same but the Minimum cathode current for regulation and the Off-state cathode current is different.
Even the TL431 has different models w/ different specs. I used part # TL431BCLPGOS and a standard Red LED which has a typical Forward voltage of 2v and 20ma.

Online Breaktru

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Re: Low Battery Indicator
« Reply #5 on: May 16, 2013, 11:43:57 AM »
I would like to point out that the resistor tolerance will play a role for a particular low voltage LED on when low as well as the TL431 on/off state. That's why I mentioned to use a 1% tolerance.
Also LED colors have different specs. Even the Red standard VS the Bright Red LED and Super Bright Red LED. Using a different LED will effect the functionality of the circuit. The circuits are revised for the standard Red LED.

Offline kortt

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Re: Low Battery Indicator
« Reply #6 on: May 17, 2013, 10:46:17 PM »
Nice! Been looking for something like this.  Thanks!  :thankyou:

Offline marlow57

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Re: Low Battery Indicator
« Reply #7 on: May 22, 2013, 10:58:00 AM »
I can use something like this. It's perfect. I'll see if my hubby can put one into my box mod

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Re: Low Battery Indicator
« Reply #8 on: May 22, 2013, 01:56:01 PM »
I installed the Low Battery Indicator circuit in my .44++ mini mod.
Works great. Low battery indication comes on at 3.03 volts.
What I like about it is you know prior to the above said voltage because you see a very dim, hardly noticeable light. When it reaches the 3.03v, the LED is very noticeable.
See the attached photos (logged on members only)
« Last Edit: May 22, 2013, 02:06:26 PM by Breaktru »

Offline jumper

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Re: Low Battery Indicator
« Reply #9 on: June 15, 2013, 08:58:58 AM »
This is a great idea. Very useful and not just cosmetic. I look forward to when I can put this on one of my mods. Love the feature. Great work!

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Re: Low Battery Indicator
« Reply #10 on: October 12, 2013, 07:19:30 PM »
Hi,I'm new to the forum sort of been a member for a while but don't post much and this is where I get a great deal of info from but I have a question what kind of resistors should I use for this I mean like carbon,metal ceramic  ,thanks

Online Breaktru

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Re: Low Battery Indicator
« Reply #11 on: October 12, 2013, 07:31:08 PM »
Hey Florida Vaper,
Any type will do. You can use a low wattage like 1/8 watt.
There are two circuits. Make sure you get the resistors for the battery voltage that you are using.

Offline been there

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Re: Low Battery Indicator
« Reply #12 on: October 13, 2013, 03:15:13 AM »
thanks Breaktru for a quick reply .    

Offline kortt

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Re: Low Battery Indicator
« Reply #13 on: December 17, 2013, 06:01:40 PM »
Breaktru, what specs are important for the shunt regulator to work correctly?  Where I want to shop only has the exact model number you listed in min order of 4000 units.  I found another one that looks similar to me but not sure of what specs to match up for it to work properly.
This is what I found:
http://canada.newark.com/on-semiconductor/tl431bilprag/ic-prog-shunt-v-ref-2-495v-0-4/dp/04R7864
Would that work?

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Re: Low Battery Indicator
« Reply #14 on: December 17, 2013, 08:14:17 PM »
I found a vendor from Canada on eBay --> TL431

The diode is a "programmable shunt regulator diode"
The Reference Input Voltage should be (Typical): 2.495v
Cathode Current: 100ma Max

Offline kortt

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Re: Low Battery Indicator
« Reply #15 on: December 18, 2013, 12:07:03 PM »
Nice, thanks Dave!  :thankyou:

Offline kortt

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Re: Low Battery Indicator
« Reply #16 on: December 23, 2013, 03:40:51 PM »
Quick question about the pins on the TL431.  Are the pins as shown in the schematic as follows?
1 = anode
2 = ref
3 = cathode
Thanks :P

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Re: Low Battery Indicator
« Reply #17 on: December 23, 2013, 04:36:00 PM »
Quick question about the pins on the TL431.  Are the pins as shown in the schematic as follows?
1 = anode
2 = ref
3 = cathode
Thanks :P

NO

My schematic shows an ON-Semiconductor diode TL431BCLPGOS.

ON-Semi TL431BCLPGOS:
1 = Ref
2= Anode
3 = Cathode

If you bought the eBay one then its a Texas Instrument TL431AILP


The Texas Instrument TL431AILP is the same pin reference as above.
« Last Edit: December 27, 2013, 09:20:34 AM by Breaktru »

Offline kortt

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Re: Low Battery Indicator
« Reply #18 on: December 23, 2013, 04:56:17 PM »
Yeah, I bought from the ebay link you provided.  I need a keeper lol, never occurred to me to compare the datasheets of the two different parts until you said that.
Thanks again Dave!   ;bow;

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Re: Low Battery Indicator
« Reply #19 on: January 10, 2014, 12:59:42 PM »
I put this little image together to help me with the 1 cell circuit that Breaktru so kindly provided.  I find having a visual representation of a circuit helps me keep things sorted and for me I can refer to it along with the schematic when I build.  Hopefully this might help someone else out as well.  I've asked Breaktru to look at it to make sure I didn't make any mistakes.  (Thanks dude!)

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Re: Low Battery Indicator
« Reply #20 on: January 10, 2014, 01:37:39 PM »
Nice going Greg  :rockin smiley: That should make it easy for those that are not schematic literate  :laughing:

Offline Visus

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Re: Low Battery Indicator
« Reply #21 on: January 10, 2014, 05:51:23 PM »
Woot
Kindergarten picture book electronics work best for visus  :thumbsup:


Offline rrtwister

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Re: Low Battery Indicator
« Reply #22 on: January 10, 2014, 07:48:47 PM »
Good job interpreting the schematic into a diagram Kortt  :thumbsup:

Offline ADozer

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Re: Low Battery Indicator
« Reply #23 on: January 15, 2014, 04:17:53 PM »
Awesome! I've been working on one of these myself, but this is super elegant :)

Offline pako75

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Re: Low Battery Indicator
« Reply #24 on: February 04, 2014, 02:00:25 PM »
Hello guys,
I was searching for a circuit to monitor the battery voltage....
i've read this post i't's excellent, but i was searching for circuit that could do something like

green - full ...... green/red - medium ....... red - low

maybe with a bicolor red/green led...

Someone has any idea???

Thank you to all

Offline columbusbk

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Re: Low Battery Indicator
« Reply #25 on: February 04, 2014, 03:16:18 PM »
Hello guys,
I was searching for a circuit to monitor the battery voltage....
i've read this post i't's excellent, but i was searching for circuit that could do something like

green - full ...... green/red - medium ....... red - low

maybe with a bicolor red/green led...

Someone has any idea???

Thank you to all

I wonder if this can be modified for our needs?
Monsoon 8

Online Breaktru

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Re: Low Battery Indicator
« Reply #26 on: February 04, 2014, 08:14:03 PM »
Hello guys,
I was searching for a circuit to monitor the battery voltage....
i've read this post i't's excellent, but i was searching for circuit that could do something like

green - full ...... green/red - medium ....... red - low

maybe with a bicolor red/green led...

Someone has any idea???

Thank you to all

Hi Pako,
I have something in mind that I can add to the existing circuit but I would like to test it out before posting the schematic. I need some time to get the parts first.

Offline pako75

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Re: Low Battery Indicator
« Reply #27 on: February 05, 2014, 12:19:31 PM »
I found this on the Bay.... but i don't know whic IC uses....

http://www.ebay.com/itm/200709081697

Offline CraigHB

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Re: Low Battery Indicator
« Reply #28 on: February 05, 2014, 02:47:59 PM »
Power consumption says 5mA which is current not power, but if it's 5mA and not 5mW, that's a bit high to leave on a battery full time.  Probably okay for removable cells, but not for permanently mounted cells.  If you were to leave your device lying around for a couple months, it would over-discharge the battery.

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Re: Low Battery Indicator
« Reply #29 on: February 05, 2014, 03:41:11 PM »
Power consumption says 5mA which is current not power, but if it's 5mA and not 5mW, that's a bit high to leave on a battery full time.  Probably okay for removable cells, but not for permanently mounted cells.  If you were to leave your device lying around for a couple months, it would over-discharge the battery.

you could power it everytime you push the atom button.... perhaps in an angel eye style button....
« Last Edit: February 05, 2014, 03:44:58 PM by pako75 »

Offline CraigHB

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Re: Low Battery Indicator
« Reply #30 on: February 05, 2014, 05:23:39 PM »
Yeah, that would solve the problem of the battery drain, but I have an indicator like that and don't often notice it (LED illuminates red when the trigger is pressed with the battery below 10% charge).  Most of the time I don't realize the battery is discharged until the mod flags a low battery and stops working.  Still it's better than nothing, but you really need a cut-out of some kind.  You could Tie that LED output to a MOSFET to switch battery power.

Offline pako75

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Re: Low Battery Indicator
« Reply #31 on: February 06, 2014, 01:38:34 PM »
You could Tie that LED output to a MOSFET to switch battery power.

I really don't how to do this...  :no: :no:

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Re: Low Battery Indicator
« Reply #32 on: February 23, 2014, 04:35:27 AM »
Hy guys,

I was thinking.....   with this revisited schematic could be possible to light the red led on the charging board????
Could be an idea to use a bicolor led to indicate both charging status and low battery.....
What do you think?

Offline aflex

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Re: Low Battery Indicator
« Reply #33 on: February 26, 2014, 12:00:29 AM »
There are two circuits. They are making a combination of parallel and series. On looking at these circuits we can realize that at least 1% tolerance and low wattage like 1 to 6 watt is require. It may vary with time.

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Re: Low Battery Indicator
« Reply #34 on: February 26, 2014, 06:29:45 AM »
There are two circuits. They are making a combination of parallel and series. On looking at these circuits we can realize that at least 1% tolerance and low wattage like 1 to 6 watt is require. It may vary with time.

Not sure what you mean. ???

Offline pako75

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Re: Low Battery Indicator
« Reply #35 on: February 26, 2014, 05:01:36 PM »
I found it!
That's what i was looking for...

Do you think this will work???

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Re: Low Battery Indicator
« Reply #36 on: February 26, 2014, 07:27:54 PM »
Yes it will work.
Looks like that the green LED will light at 3.5v or above and go out when the voltage is 3.4v or below. The red LED will light at 3.4v and below.

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Re: Low Battery Indicator
« Reply #37 on: February 27, 2014, 01:48:36 PM »
Tried today..... doesn't work!  :wallbash:

At 4.2V the red led is enough bright, at 3.5V very low red light...
Green led lights (very low) at 3.1V....
transistor BC547C



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Re: Low Battery Indicator
« Reply #38 on: February 27, 2014, 04:30:42 PM »
Are you certain of the pins and the position of the transistor when reading the pin numbers:
Looking at it with the pins facing down and the flat side toward you,
from left to right........
1. Collector 2. Base 3. Emitter
« Last Edit: February 27, 2014, 04:35:52 PM by Breaktru »

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Re: Low Battery Indicator
« Reply #39 on: February 27, 2014, 05:18:43 PM »
Tomorrow i'll check this, but i'm pretty sure i wired it correctly
I've controlled the datasheet before start wiring....

Offline ChainVaper

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Re: Low Battery Indicator
« Reply #40 on: February 27, 2014, 08:56:14 PM »
I just noticed something.
The schematic shows a BC547 and you used a BC547C transistor.
Don't know if that has anything to do with it  :Thinking:

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Re: Low Battery Indicator
« Reply #41 on: April 23, 2014, 12:45:25 PM »
I just built one using the TL431. Thanks breaktru. It works great  :thumbsup:

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Re: Low Battery Indicator
« Reply #42 on: May 07, 2014, 03:52:52 AM »
I found it!
That's what i was looking for...

Do you think this will work???

Hello to all, New member and noob to circuitry but looking to build my first mod and is there schematic yet for a dual battery set up? Or is the schematic posted by Breaktru the same and uses a red and green led as it was not specified?
« Last Edit: May 07, 2014, 04:06:38 AM by blkbd »

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Re: Low Battery Indicator
« Reply #43 on: May 08, 2014, 09:11:30 PM »
Hi blkbd I saw your post on ecf too.

Breaks 1st diagram will work for you on the okr with 8.4v  you will have to figure a different resistor if its not a standard led.  That will be cool, his circuit is designed to light when the voltage reaches ~6v its off until then.. 

Off post:
Heres a really cool indicator for a single cell
https://www.fasttech.com/product/1225203

Offline blkbd

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Re: Low Battery Indicator
« Reply #44 on: May 09, 2014, 04:27:31 AM »
Why 2 LED's? Sorry I can do basic wiring and soldering but all these LED's and resistors make my head swim.

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Re: Low Battery Indicator
« Reply #45 on: May 09, 2014, 11:33:36 AM »
Why 2 LED's? Sorry I can do basic wiring and soldering but all these LED's and resistors make my head swim.

He wired them in series-- he says, the posted diagram is for a single 2v 20ma led,  he obviously used a different method of achieving same results but with two instead of one.

Re-read his first post.

Pako then later finds a diagram at another site that shows full battery  green led emit and discharged showing red led emit but he never got it to work properly since his last post..  Noone else has tried that diagram or has posted about trying it.  Breaks diagram works as posted @~6v..

This may be to advanced for ya but its really not difficult at all, its a very simplistic design just make sure you buy the right parts.


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Re: Low Battery Indicator
« Reply #46 on: May 09, 2014, 05:52:49 PM »
Thank you for your patience, :thumbsup: I did read it but got to fixated on the diagram and pic trying to understand it. The Kortt diagram is the kind that I can follow. I don't see any spec's on what LED to use with Breahtru's diagram? But would guess this one http://www.radioshack.com/product/index.jsp?productId=2062554&znt_campaign=Category_CMS&znt_source=CAT&znt_medium=RSCOM&znt_content=CT2032233
 Thank you for your time.  :beer-toast:
« Last Edit: May 09, 2014, 05:58:22 PM by blkbd »

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Re: Low Battery Indicator
« Reply #47 on: May 09, 2014, 07:08:08 PM »
A standard Red LED has a typical Forward voltage of 2v and 20ma. The link to your RS LED is 2.25v, 28ma. You would have to tweak the resistors to work with that LED. Or find a typical Red LED like THIS
« Last Edit: May 09, 2014, 07:17:03 PM by Breaktru »

Offline blkbd

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Re: Low Battery Indicator
« Reply #48 on: May 09, 2014, 07:53:25 PM »
Thanks for that info, Looks like I have some sketching to do and a weekend project.

Offline Jasen

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Re: Low Battery Indicator
« Reply #49 on: May 10, 2014, 04:08:57 PM »
Finding someone that stocks those resistors in a through hole configuration is proving to be challenge, Digikey, mouser are pretty much a no go, all I'm finding from them is SMD's

Breaktru Forum  |  eCigarette Forum  |  Modding  |  Topic: Low Battery Indicator
 

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