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Forget about capacitance meters - an ESR meter is the way to go when it comes to identifying
faulty electrolytics. This well-proven design is autoranging, low in cost and simple to build.
TS HARD TO BELIEVE that its meter kits have now been sold and sales sary to understand why they cause so
I already eight years since my first ESR
(equivalent series resistance) meter was
(mainly outside Australia) continue to be
strong.
many electronic faults.
Fig.1 is a simplified cross-section
described in the January 1996 edition Over those eight years, both Dick drawing which shows the basics. As with
of Electronics Australia. It was Smith Electronics (which sells the kit) many other kinds of capacitors, the
designed on a 386 PC! and the author have received many sug- plates of an electrolytic consist of two
The ESR meter allowed service techni- gestions from constructors on improving long aluminium foil strips wound into a
cians to quickly and easily identify the ESR meter kit particularly on mak- cylinder. The big difference is that the
defective electrolytic capacitors while ing the construction easier. This upgrad-
they were still in circuit. It measures a ed version is the result and incorporates
characteristic of electrolytic capacitors many of those ideas. As before, it will be
which is very important: the equivalent available as a complete kit from DSE.
series resistance or ESR. Whats ESR?
Back then, no-one (including myself)
expected that a meter designed to meas- Before taking a look at whats changed
ure a capacitor characteristic hardly any- in this Mk2 version of the ESR meter,
one had ever heard of would become lets take a look at what an ESR meter
popular in Australia, let alone overseas. does. First, we need to get into a bit of
However, we didnt consider the explo- boring theory to understand how elec-
sive growth of the Internet. Thanks to trolytic capacitors (which Ill refer to
people discussing it on various news- simply as electrolytics from here on)
groups and by email, about 12,000 ESR are constructed and work. This is neces-
Fig.5: a Zilog Z86E0412 programmed microcontroller (IC2) forms the heart of the circuit. This IC automatically switches
transistors Q3-Q5 to set the pulse current level, while Q7 & Q8 amplify the resultant voltage pulses across the test capac-
itor for comparison with a reference voltage ramp (across C10).
Fig.7: the PC board is attached to the underside of the front panel using 15mm-long tapped spacers, flat washers and M3
x 6mm machine screws.
detected a problem. In that case, go to the are supplied with these sockets. As metal panel, thereby short-circuiting
Fault Codes panel to find out what to shown in Fig.7, these must be installed them! Also refer to Fig.11 for correct
check for. between the lugs and the front panel, not socket mounting.
At this point, you can mount the test under the tops of the sockets. Many con- Next, mount the pushbutton switch,
lead sockets onto the front panel see structors of the Mk.1 version overlooked using small pliers to gently tighten the
Fig.7. Note that plastic insulating rings this and placed the lugs directly on the nut and being careful not to slip and
scratch the panel. That done, fasten the
Table 1: Resistor Colour Codes standoffs to the board using 3mm
screws, then mount the whole assembly
Value 4-Band Code (1%) 5-Band Code (1%) on the front panel using the black coun-
470k yellow violet yellow brown yellow violet black orange brown
tersunk 3mm screws supplied. If the
220k red red yellow brown red red black orange brown LED displays foul the Perspex window,
100k brown black yellow brown brown black black orange brown use the supplied washers to further space
47k yellow violet orange brown yellow violet black red brown the board from the front panel.
15k brown green orange brown brown green black red brown Finally, complete the assembly by con-
10k brown black orange brown brown black black red brown necting the wires to the pushbutton
6.8k blue grey red brown blue grey black brown brown switch and test lead sockets, and by sol-
4.7k yellow violet red brown yellow violet black brown brown dering the supply leads to the battery
2.7k red violet red brown red violet black brown brown holder. See Fig.10a & 10b.
2.2k red red red brown red red black brown brown
Calibration
1k brown black red brown brown black black brown brown
680 blue grey brown brown blue grey black black brown Now for the calibration. The step-by-
220 red red brown brown red red black black brown
step procedure is as follows:
180 brown grey brown brown brown grey black black brown
(1) Plug in the test leads, then push the
100 brown black brown brown brown black black black brown
button. You should see - on the left-
68 blue grey black brown blue grey black gold brown
5.6 green blue gold brown green blue black silver brown
hand display, indicating that the meter is
seeing an ESR/resistance thats greater
BC338 Q12
a k a k a k a k
220uF C3
LED1 LED2 LED1 LED2
4.7k R27
4.7k C4 R28
100nF
100nF
C13
2.2k R9
BC328 59/9 ....BOBIC3 Q5 59/9 ....BOB
2.2k R7 IC3
4094
100R 2.2k R10 R5
BC328 Q4
470nF C10
BC558
1k IC2 R8 Q10
47k
R4
IC2
BC328 Z86E0412 Q3 Q11
BC338
10k BC558 R6 Q9
R20
R19
10k
3.58MHz
10k
R11
27pF 27pF D3 C11 C12
220uF
10k C9 R21
D4
R29
2.7k
RCS Radio
D2
RCS Radio
BC558
100nF
15k C6 R13 Q7 Q8 R3
C5
47uF BP 100k
22uF Q2
RCS Radio
6.8k BC338 RCS Radio
C8 R17
R12
4148
D5
15k R26
1k
R14
1N4148
220k
4.7k
R2
D1
RCS Radio
VR1 D6
RCS Radio
4148 VR1
180R
VR2
R16
10K
RCS Radio
VR2
RCS Radio
33n
C7
100nF 200R C2
78L05
R23 IC1
10k
47k R25
Q1 R1
BC328 10k
100uF C1
- - +
o
+
o
- - +
CAP ON TEST BATT BUTTON CAP ON TEST BATT BUTTON
Fig.9a & 9b: Shows the PCB overlay with both component values and component designations. This can be very helpful
in a service or fault-finding situation when the constructor needs to cross-reference between the two.
plastic
washer ring
solder nuts
lug
Fig.12: The milled Perspex window should be of snug fit inside the front
panel cut-out. At times, paint over-spray on the inner edge of the cut-out
may prevent the window from fitting correctly. If this occurs it will be nec-
essary to file smooth the vertical milled edge until a perfect fit is achieved.
Finally, a small drop of contact adhesive at each corner of the display will
hold and secure the window in place.
Screw PH
M3 x 6mm Case
Battery Holders Screw PH
M3 x 6mm
Doube-sided tape
Fig.13: the battery holder is positioned on the bottom of the case and held in place by double sided tape.
Text and illustrations courtesy of Silicon Chip Dick Smith Electronics ZA8819 - 1