circuit

T
here are many ways of battery
charging but constant-current
charging, in particular, is a
popular method for lead-acid and Ni-
Cd batteries. In this circuit, the battery
is charged with a constant current that
is generally one-tenth of the battery
capacity in ampere-hours. So for a
4.5Ah battery, constant charging cur-
rent would be 450 mA.
This battery charger has the follow-
ing features:
1. It can charge 6V, 9V and 12V bat-
teries. Batteries rated at other voltages
can be charged by changing the values
of zener diodes ZD1 and ZD2.
2. Constant current can be set as
per the battery capacity by using a
potmeter and multimeter in series with
the battery.
3. Once the battery is fully charged,
it will attain certain voltage level (e.g.
13.5-14.2V in the case of a 12V battery),
give indication and the charger will
switch off automatically. You need not
remove the battery from the circuit.
4. If the battery is discharged be-
low a limit, it will give deep-discharge
indication.
5. Quiescent current is less than 5
mA and mostly due to zeners.
6. DC source voltage (V
CC
) ranges
from 9V to 24V.
7. The charger is short-circuit pro-
tected.
D1 is a low-forward-drop schottky
diode SB560 having peak reverse volt-
age (PRV) of 60V at 5A or a 1N5822
diode having 40V PRV at 3A. Nor-
mally, the minimum DC source volt-
age should be D1 drop+Full charged
battery voltage+V
DSS
+ R2 drop, which
is approximately Full charged battery
voltage+5V. For example, if we take
full-charge voltage as 14V for a 12V
battery, the source voltage should be
14+5=19V.
For the sake of simplicity, this con-
stant-current battery charger circuit is
divided into three sections: constant-
current source, overcharge protection
and deep-discharge protection sec-
tions.
The constant-current source is
built around MOSFET T5, transistor
T1, diodes D1 and D2, resistors R1, R2,
R10 and R11, and potmeter VR1. Diode
D2 is a low-temperature-coeffcient,
highly stable reference diode LM236-5.
LM336-5 can also be used with reduced
operating temperature range of 0 to
+70C. Gate-source voltage (V
GS
)

of T5
is set by adjusting VR1 slightly above
4V. By setting V
GS
, charging current
can be fxed depending on the battery
capacity. First, decide the charging
current (one-tenth of the batterys Ah
capacity) and then calculate the nearest
standard value of R2 as follows:
R2 = 0.7/Safe fault current
Constant-Current
Battery Charger
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electroni cs for you August 2009 115 w w w . e f y m A g . c o m
R2 and T1 limit the charging cur-
rent if something fails or battery termi-
nals get short-circuited accidentally.
To set a charging current, while
a multimeter is connected in series
with the battery and source supply is
present, adjust potmeter VR1 slowly
until the charging current reaches its
required value.
Overcharge and deep-discharge
protection have been shown in dotted
areas of the circuit diagram. All com-
ponents in these areas are subjected to
a maximum of the battery voltage and
not the DC source voltage. This makes
the circuit work under a wide range of
source voltages and without any infu-
ence from the charging current value.
Set overcharge and deep-discharge
voltage of the battery using potmeters
VR1 and VR2 before charging the bat-
tery.
In overcharge protection, zener
diode ZD1 starts conducting after
its breakdown voltage is reached,
i.e., it conducts when the battery
voltage goes beyond a prefxed high
level. Adjust VR2 when the battery
is fully charged (say, 13.5V in case of
a 12V battery) so that V
GS
of T5 is set
to zero and hence charging current
stops fowing to the battery. LED1
glows to indicate that the battery is
fully charged. When LED1 glows, the
internal LED of the optocoupler also
glows and the internal transistor con-
ducts. As a result, gate-source voltage
(V
GS
) of MOSFET T5 becomes zero and
charging stops.
Normally, zener diode ZD2 con-
ducts to drive transistor T3 into con-
duction and thus make transistor T4
cut-off. If the battery terminal voltage
drops to, say, 11V in case of a 12V bat-
tery, adjust potmeter VR3 such that
transistor T3 is cut-off and T4 conducts.
LED2 will glow to indicate that the bat-
tery voltage is low.
Values of zener diodes ZD1 and
ZD2 will be the same for 6V, 9V and
12V batteries. For other voltages, you
need to suitably change the values of
ZD1 and ZD2. Charging current pro-
vided by this circuit is 1 mA to 1 A, and
no heat-sink is required for T5. If the
maximum charging current required is
5A, put another LM236-5 in series with
diode D2, change the value of R11 to 1
kilo-ohm, replace D1 with two SB560
devices in parallel and provide a good
heat-sink for MOSFET T1. TO-220 pack-
age of IRF540 can handle up to 50W.
Assemble the circuit on a gen-
eral-purpose PCB and enclose in a
box after setting the charging current,
overcharge voltage and deep-discharge
voltage. Mount potmeters VR1, VR2
and VR3 on the front panel of the
box.
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circuit
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electroni cs for you March 2009 81 w w w . e f y M a g . c o M
Sandip Trivedi and p.d. LeLe
TripLe power SuppLy
in positive and negative regulated
power supplies. LED1 glows to indi-
cate that +5V is available, while LED2
indicates that 5V is available.
Switch S1 is used for mains on/
off. Using switches S2 through
S4, any of the three supplies can be
independently turned off when not
required in a particular experiment.
This reduces unnecessary power dis-
sipation and increases the life and
reliability of the power supply. Since
the circuit uses three terminal regula-
tors, only capacitors are required at
the input and output. The use of few
components makes the circuit very
simple. The three terminal regulators
have heat-sink provision to directly
deliver 1A output current. To ensure
the maximum output, do not forget to
T
his low-cost, multipurpose
power supply fulfils the re-
quirements of almost all labora-
tory experiments. Nonetheless, it can
be easily fabricated by hobbyists.
A single transformer is used to
build this triple power supply. Regula-
tor IC LM317 generates variable power
supply of 1.25 to 20V, 1A. The dual
12V, 1A power supply is generated
by regulators 7812 and 7912. Similarly,
dual 5V, 1A power supply is gener-
ated by regulators 7805 and 7905.
On/off switches (S2 through S4)
select the required power supply. Vari-
able power supply is used to study the
characteristics of devices. Fixed +5V
power supply is used for all digital,
microprocessor and microcontroller
experiments. Dual 12V power supply
is used for op-amp-based analogue
circuit experiments.
Fig. 1 shows the circuit of the triple
power supply, while Fig. 2 shows the
pin configuration of the regulators
used in the circuit. Transformer X1
steps down the mains power to deliver
the secondary output of 18V-0-18V.
The transformer output is rectifed by
full-wave bridge rectifer BR1, fltered
by capacitors C1, C2, C3, C7 and C8,
and regulated by IC1 through IC5.
Regulator IC1 (LM317) provides vari-
able voltages (1.25 to 20V), while IC2
and IC4 provide regulated +12V and
12V, respectively. The output of IC2 is
fed to regulator IC3 (7805), which pro-
vides fxed +5V. Similarly, the output
of IC4 is fed to regulator IC5 (7905),
which provides fxed 5V. Capacitors
C4 through C6, and C9 through C11,
are used for further fltering of ripples
Fig. 1: Tripple power supply
OUT IN
IC3
1
7805
2
3
GND
F1
1.5A
FUSE
S1
ON/OFF
SWITCH
S2
230V AC
50Hz
L
N
X1
BR1
W04
C1
1000
35V
C5
10
16V
C4
100
25V
C9
100
25V
C2
0.1
C3
0.1
C6
0.1
C8
0.1
C11
0.1
C10
10
16V
C7
1000
35V
S3
S4
R2
330
R1
120
R3
330
LED1
LED2
GND
GND
+5V
5V
OUT IN
IC2
1
7812
2
3
GND
OUT IN
IC4
2
7912
1
3
GND
OUT IN
IC5
2
7905
1
3
GND
OUT IN IC1
3
LM317
1
2
ADJ.
VR1
2.2K
+1.25 TO 20V
+12V
12V
X1 = 230V AC
PRIMARY TO 18V-0-18V,
1.5A SECONDARY
TRANSFORMER
BR1-W04
1.5A, BRIDGE
RECTIFIER
GND
BR1
W04
HEAT SINK
HEAT SINK
HEAT SINK HEAT SINK
HEAT SINK
S2 = FOR VARIABLE VOLTAGE
S3 = FOR +12V AND +5V
S4 = FOR 12V AND 5V
S1-S4 = ON/OFF SWITCH
POT
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82 March 2009 electroni cs for you www. e f y Ma g . c o M
use heat-sinks for the regulators.
The three-terminal regulators are
almost non-destructible. These have
inbuilt protection circuits including
the thermal shutdown protection. Even
if there is overload or shorting of the
output, the inbuilt overload protection
circuit will limit the current and slowly
reduce the output voltage to zero.
Similarly, if the temperature increases
beyond a certain value due to excessive
load and heat dissipation, the in-built
thermal shutdown circuit will reduce
the output current and the output volt-
age (gradually) to zero. Thus complete
protection is provided to the circuitry.
Assemble the circuit on a general-
purpose PCB and enclose in a box as
shown in Fig. 3.
The step-by-step procedure to build
the triple power supply for the labora-
tory follows:
Fig. 2: Pin confgurations of regulators
Fig. 3: Proposed cabinet for power supply
1. Collect all the components shown
in the circuit diagram.
2. Connect switch S1, fuse, trans-
former and mains cord to the assem-
bled PCB as well as the box.
3. Keep the multimeter in DC volt-
age range (more than 25V DC) and
measure the DC voltage across ca-
pacitors C1 and C7 (1000 F, 35V). This
voltage should be around 18V1.41=25
to 26V DC. Check both positive and
negative voltages with respect to
ground.
4. It is advisable to use three-wire
mains cable and plug. If you are using
any metallic box, earthing wire/pin of
the mains plug should be soldered to
the body of the metallic box using an
earthing tag.
5. If the 18V-0-18V
transformer is replaced
with 15V-0-15V trans-
f ormer, t he out put
voltage of the variable
supply using LM317
will be correspond-
ingly lower.
6. If proper voltages
are available, go to step
7. Otherwise, check the
connections.
7. Connect variable regulator
LM317 to the circuit and check 1.25V
to 20V output by varying the 2.2-kilo-
ohm linear potentiometers.
8. Now connect ICs 7812, 7912, 7805
and 7905 to the circuit and check their
output voltage.
9. Connect terminals, potmeter,
switches and indicator LED on the
front panel of the box and complete
the connections. Close the box by us-
ing screws.
Precaution. At the primary side of
the transformer, 230V AC could give
lethal shocks. So be careful not to touch
this part. EFY will not be responsible
for any resulting loss or harm to the
user.
circuit
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88 apri l 2009 electroni cs for you www. e f y ma g . c o m
D. Mohan KuMar
reMote-operateD Master switch
S.C. DW
IVEDI
tial divider comprising resistors R4 and
R5 maintains half of 5.1V at pin 2 of
IC1. In brief, the voltage at pin 2 of IC1
is higher than at pin 3 and its output
remains low. LED2 remains off and
transistor T2 does not conduct. Relay
RL1 remains de-energised and, as a re-
sult, security lamps (both indoors and
outdoors) remain switched off.
When you press any key of the
remote TV handset, IR rays fall on the
receiver (IRX1) and its output goes low.
LED1 fashes in sync with pulsation of
the IR rays. At the same time, transis-
tor T1 (BC558) conducts to take pin 3 of
IC1 high. IC1 is used as a comparator
with timer action.
When transistor T1 conducts, pin 3
of IC1 gets a higher voltage than pin 2
making the output of IC1 high. Mean-
while, capacitor C4 charges to full
voltage and keeps pin 3 high for a few
minutes even after T1 is non-conduct-
ing. Resistor R3 provides discharge
path for capacitor C4, which decides
the time period for which the output of
comparator IC1 should remain high.
The high output of IC1 energises re-
lay RL1 through relay-driver transistor
T2. Thus the load, i.e., security lamps,
turn on for three to four minutes. LED2
glows to indicate activation of the
relay as well as switching on of the
security lights. Connect a single-pole,
single-throw on/off switch (MS) to
activate the security lamps manually
when required.
Zener diode ZD1 provides 5.1V DC
for safe operation of the IR receiver
and associated circuit. Power for the
circuit is derived from a step-down
transformer (X1) and a bridge recti-
fer comprising diodes D1 through D4.
Smoothing capacitor C1 removes rip-
ples, if any, from the power supply.
Assemble the circuit on a general-
purpose PCB and enclose in a suitable
cabinet. Drill holes on the front panel
for mounting the IR sensor and LEDs.
Connect the master switch between the
normally-open (N/O) contact and pole
of relay RL1 so that the master switch
can be used when needed. The relay
contacts rating should be more than
4A. Mount the unit near the master
switch using minimal wiring.
G
enerally, a bedside master
switch is used to switch
on lamps both indoors and
outdoors when there is a threat of
intruder. This circuit can be used to
activate the master switch from the
bed without searching for the switch
in darkness. It can be activated by the
TV remote handset. The security lamps
glow for three minutes and then turn
off. The circuit is sensitive and can be
activated from a distance of up to 25
metres.
IR receiver module TSOP 1738
(IRX1) is used to sense the pulsed
38kHz IR rays from the TV remote
handset. The IR receiver module has
a PIN photodiode and a preamplifer
enclosed in an IR flter epoxy case. Its
open-collector output is 5 volts at 5mA
current in the standby mode.
In the standby mode, no IR rays
from the remote handset fall on the IR
receiver, so its output pin 3 remains
high and LED1 doesnt glow. Through
resistor R2, the base of transistor T1
remains high and it does not conduct.
As a result, the voltage at pin 3 of IC
CA3130 (IC1) remains low. The poten-
circuit
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94 December 2009 electroni cs for you www. e f y ma g . c o m
T
oday telephone has become
an integral part of our lives.
It is the most widely used
communication device in the world.
Owing to its immense popularity and
widespread use, there arises a need for
call recording devices, which fnd ap-
plication in call centres, stock broking
frms, police, offces, homes, etc.
Here we are describing a call re-
corder that uses very few components.
But in order to understand its working,
one must frst have the basic knowl-
edge of standard telephone wiring and
a stereo plug.
In India, landline telephones pri-
marily use RJ11 wiring, which has
two wirestip and ring. While tip is
the positive wire, ring is the negative
one. And together they complete the
telephone circuit. In a telephone line,
voltage between tip and ring is around
48V DC when handset is on the cradle
(idle line). In order to ring the phone
for an incoming call, a 20Hz AC cur-
rent of around 90V is superimposed
over the DC voltage already present in
the idle line.
The negative wire from the phone
line goes to IN1, while the posi-
tive wire goes to
IN2. Further, the
negative wire from
OUT1 and the posi-
tive wire from OUT2
are connected to the
phone. All the resis-
tors used are 0.25W
carbon flm resistors
and all the capaci-
tors used are rated for 250V or more.
The negative terminal of To AUX IN
is connected to pin 1 of the stereo jack
while the positive terminal is con-
nected to pins 2 and 3 of the stereo
jack. This stereo jack, in turn, is con-
nected to the AUX IN of any recording
device, such as computer, audio cas-
sette player, CD player, DVD player,
etc. Here we shall be connecting it to
a computer.
When a call comes in, around 90V
AC current at 20Hz is superimposed
over the DC voltage already present in
the idle line. This current is converted
into DC by the diodes and fed to resis-
tor R1, which reduces its magnitude
and feeds it to LED1. The current is
further reduced in magnitude by the
resistor R2 and fed to the right and
left channels of the stereo jack, which
are connected to the AUX IN port of a
computer.
Any audio recording software,
such as AVS audio recorder (available
at: http://www.avs4you.com/AVS-
Audio-Recorder.aspx), Audacity audio
recorder (http://audacity.sourceforge.
net/), or audio recorder (http://www.
audio-tool.net/audio_recorder_for
_free.html), can be used to record the
call. When a call comes in, one needs
to launch the audio recording software
and start recording.
For phone recording, simply con-
nect the stereo jack to the AUX IN
port of the PC. Install the Audacity
audio recorder (different versions are
available for free for different op-
erating systems at http://audacity.
sourceforge.net/) on your PC. Run
the executable Audacity fle. In the
main window, you will fnd a drop-
down box in the top right corner.
From this box, select the AUX option.
Now you are ready to record any call.
As soon as a call comes in, press the
record button found in the Audacity
main window and then pick up the
telephone receiver and answer the
call. Press the stop button once the
call ends. Now go to the fle menu and
select the Export as WAV option and
save the fle in a desired location.
You may change the value of resis-
AlizishAAn KhAtri
telephone cAll recorder
S.C. DW
IVEDI
Fig. 1: Call recorder circuit
Fig. 2: Pin confguration of stereo jack
Fig. 3: RJ connector
circuit
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electroni cs for you December 2009 95 www. e f y ma g . c o m
tor R2 if you want to change the output
volume. You can use a variable resistor
in series with R2 to vary the volume of
the output. The recorded audio clip can
be edited using different options in the
Audacity software.
You can assemble the circuit on a
general-purpose PCB and enclose it in
a small cabinet. Use an RJ11 connec-
tor and stereo jack for connecting the
telephone set and computer (for call
recording). Telephone cords can be
used to connect to the phone line and
the circuit. Use of a shielded cable is
recommended to reduce disturbances
in the recording. These can also be
reduced by increasing the value of R2
to about 15 kilo-ohms.
EFY note. Audacity recording
software is included in this months
EFY-CD under Utilities section.
circuit
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electroni cs for you December 2009 93 www. e f y ma g . c o m
power is available, diode D5 forward
biases. It provides power to the circuit
and also charges the battery through
resistor R2, and it limits the charging
current to 120 mA. When power fails,
diode D5 reverse biases and diode D6
forward biases, giving instant backup
to the circuit. LED1 indicates the avail-
ability of mains power.
Assemble the circuit on a general-
purpose PCB and enclose it in a suit-
able case. Connect the piezo element
to the circuit using a thin insulated
wire. Glue the fat side of the piezo el-
ement on a 3030cm aluminium sheet
to increase its sensitivity. Fix the sheet
with the piezo sensor to the site where
protection is needed. The remaining
circuit can be fxed at a suitable place.
If only the alarm generator is needed,
omit the relay driver section.