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361 lines
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361 lines
21 KiB
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<td class="c" id="displayYearEl" title="You are here: 08:40:10 Apr 06, 2012">2012</td>
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<a class="t" href="http://web.archive.org/web/20120406084010*/http://members.shaw.ca/swstuff/esrmeter.html" title="See a list of every capture for this URL">74 captures</a>
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<div class="r" title="Timespan for captures of this URL">09 Apr 2005 - 17 Mar 2017</div>
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<a id="wm-expand" class="wm-btn wm-closed" href="#expand" onclick="__wm.ex(event);return false;"><span id="wm-expand-icon" class="iconochive-down-solid"></span> <span style="font-size:80%">About this capture</span></a>
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<div style="background-color:#666;color:#fff;font-weight:bold;text-align:center">COLLECTED BY</div>
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<span class="c-logo" style="background-image:url(https://archive.org/services/img/webwidecrawl);"></span>
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Organization: <a style="color:#33f;" href="https://archive.org/details/webwidecrawl" target="_new"><span class="wm-title">Internet Archive</span></a>
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The Internet Archive discovers and captures web pages through many different web crawls.
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At any given time several distinct crawls are running, some for months, and some every day or longer.
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View the web archive through the <a href="http://archive.org/web/web.php">Wayback Machine</a>.
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<span class="c-logo" style="background-image:url(https://archive.org/services/img/wikipediaoutlinks00003)"></span>
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<div>Collection: <a style="color:#33f;" href="https://archive.org/details/wikipediaoutlinks00003" target="_new"><span class="wm-title">Wikipedia Outlinks February 2012</span></a></div>
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<div style="position:absolute;top:0;left:0;width:100%;height:75px;background:linear-gradient(to bottom,rgba(255,255,255,0) 0%,rgba(255,255,255,0) 90%,rgba(255,255,255,255) 100%);"></div>
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Crawl of outlinks from wikipedia.org started February, 2012. These files are currently not publicly accessible.
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<div style="background-color:#666;color:#fff;font-weight:bold;text-align:center" title="Timestamps for the elements of this page">TIMESTAMPS</div>
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<!-- Copyright (C) 2009 Lawrence P. Glaister. All rights reserved. -->
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<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/lpglogo.jpg" alt="Logo" height="184" width="277"><strong>
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<font size="7"><i>Capacitor ESR Tester</i></font>
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</strong></p><strong>
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<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/spectbar.gif" height="7" width="573"></p>
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<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/esrproto03.jpg" alt="protoype esr meter" border="5"></p>
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<strong>
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<h1>Project Description</h1>
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This project was conceived as a way to enhance the collection of test equipment on my test bench.
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I buy a lot of older HP test gear off ebay as well as older radios. Most of this gear is 25-60 years old
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and needless to say, the condition of the electrolytic capacitors is somewhat suspect. I needed a way to
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quickly weed out bad caps with an in circuit tester.<br>
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At the present time, there are no plans to market circuit boards, kits, parts or complete units
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for sale.
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<h2>What is ESR?</h2>
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"ESR" stands for equivalent series resistance. ESR is one of the
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characteristics that defines the performance
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of an electrolytic capacitor. Low ESR is highly desirable in a capacitor
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as any ripple current through the
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capacitor causes the capacitor to heat up due to the resistive loses.
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This heating accelerates
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the demise of the capacitor by drying out the electrolyte at an ever
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increasing rate.
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Over the lifetime of a capacitor, it is not uncommon for the ESR to
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increase by a factor of 10 to 30 times
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or even go open circuit. Typical lifetime ratings for electrolytics are
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2000-15000 hours and are very dependant on ambient operating
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temperature. As the ESR increases, the filtering operation of the
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capacitor becomes impaired
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and eventually the circuit fails to operate correctly.
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<h2>Why are ESR Meters so Useful?</h2>
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A typical capacitor checker measures the capacity (usually in micro
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farads) of the test capacitor.
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Some advanced units also test for leakage current. Most of these testers
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require that the capacitor be
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removed from the circuit. Unless the capacitor has totally failed, they
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will not detect a high ESR value.
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In a typical circuit, there may be 10's or 100's of capacitors. Having
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to remove each one for testing is very
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tedious and there is a great risk of damaging circuit boards. This
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tester uses a low voltage ( 250mv )
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high frequency (150khz) A/C current to read the ESR of a capacitor in
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the circuit. The in circuit testing
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is possible because of the low voltage used for obtaining the
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measurement. The voltage is low enough that
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solid state devices in the surrounding circuitry are not activated and
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do not affect the low resistance reading we are attempting to obtain. A
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lot of capacitor checkers will be damaged if you happen to test a
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charged capacitor.
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This circuit is A/C coupled and will withstand up to 400vdc of charge on
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a capacitor (but watch your fingers!).
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The ESR checker will not detect shorted capacitors as they will read
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with a very low ESR value. If you are trouble shooting a circuit, you
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will have to use several instruments including your nose, voltmeter and
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oscilloscope to locate all the possible failure modes. My experience has
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found that the ESR meter catches about 95% of capacitor problems and
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potential problems.
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<h2>Features</h2>
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<ul>
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<li>Tests electrolytic capacitors > 1uf in circuit.</li>
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<li>Caps may be tested in circuit or by bridging them across the terminal posts or using test leads.</li>
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<li>Polarity insensitive testing.</li>
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<li>Tolerates charged capacitors up to 400vdc.</li>
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<li>Low battery draw (approx 25ma) resulting in about 20 hours of battery time when using 4 cheap AA nicads.</li>
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<li>Easy to read analog meter.</li>
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<li>Measures ESR range from 0-75ohms with an expanded scale A/C ohmmeter.</li>
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</ul>
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<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/esrproto01.jpg" border="5" height="480" width="640"></p>
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<h2>Circuit Description</h2>
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See the schematic for component designations.
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The circuit starts with a 150khz oscillator using one gate of a 74hc14.
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The rest of the gates are used as
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buffers to increase the current drive to the low pass filter. The single
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pole low pass filter is necessary because the square wave signal
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contains a lot of energy in high frequency odd order harmonics. The
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output of the filter is applied across a 10 ohm load resistor that
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provides the low impedance drive signal to the test capacitor. Diodes D5
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and D6 protect the circuit from discharge spikes if you happen to test a
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charged capacitor. R18 is used to discharge C5 so that you don't blow
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up anything if you alternately test charged high and low voltage caps.
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C5 isolates the test circuit from DC voltages up to 400 volts.
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<br>
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<br>Be careful if you are testing high voltage capacitors... the safest
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way to work is to make sure the test capacitors are discharged <b>before</b>
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testing them. Be aware that high voltage capacitors can hold a lethal
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charge for several days depending on the circuit design. I learned this
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first hand in high school electronics class. Students (not to be named!)
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used to charge the caps and put them back on the shelf for the next
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unsuspecting victim to pick up.
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<br>
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<br>The rest of the circuit is a very straight forward transistor
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amplifier with a gain of about 10.5. This amplifies the
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A/C signal passed through the test capacitor up to several volts in
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amplitude. The signal is then coupled to a full
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wave bridge rectifier that has the meter as its load. The threshold
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voltage of the bridge rectifier is used to an advantage and provides the
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expanded scale function of the ohm meter. The amplified voltage from
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the test capacitor must be great enough to overcome 2 diode drops before
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the meter will start to respond. This sets the high resistance
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threshold for the meter at somewhere between 75-100 ohms. The meter is
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zeroed by shorting the test leads together and adjusting the pot in the
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meter circuit for a full scale ( 0 ohms )reading on the meter. Proper
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operation of the circuit can be verified by checking several values of
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resistors with the meter. Shorted leads should indicate full scale, a 1
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ohm resistor should read about 90% of full scale, a 10 ohm resistor
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should read about 40% of full scale and a 47 ohm resistor should barely
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move the needle to about 10% of FSD. The absolute readings will vary
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with temperature and battery voltage, but the idea is that most ESR
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values should be much less than 10 ohms which means good caps test at
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very close to full scale and bad caps test at little or no deflection.
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<br>
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The board below shows my second prototype. The top 2 wires run to the
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front panel banana test jacks, the middle 2 wires are the incoming
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switched 5 volts from the 4 AA nicads, and the bottom 2 wires run to the
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series combination of the zero adjust pot and the meter on the front
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panel.
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<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/esrproto02.jpg" border="5" height="480" width="640"></p>
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<h3>Project Files</h3>
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Schematic Drawing - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esrschematic.png">esrschematic.png(94.7K)</a> <br>
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Parts Layout - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esrbuildit.png">esrbuildit.png(13.4K)</a> <br>
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PCB bottom view - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esrpcb.png">esrpcb.png(4.8K)</a> <br>
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PCB Xray View - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esrxray.png">esrxray.png(4.8K)</a> <br>
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Eagle PCB files - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esrmeter-9mar05.tgz">esrmeter-9mar05.tgz(173.2K)</a> <br>
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LTSpice/SWCadiii - <a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/esr.asc">Linear Technology Spice model esr.asc(5.8k) </a> <br>
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<h1>System Requirements</h1>
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This circuit was first prototyped using a homebuilt prototyping panel.
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As you can see by the picture above,
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it was ugly but it worked. My final version was hand built on a "pad per
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hole" prototyping board with 0.1" spacing.
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I used the PCB layout as a guide for placing and wiring the components
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(printed and glued to proto board). I did the PCB design as part of the
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project
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so that I could optimize the board size and parts placement. The pcb is
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roughly 2x3" and is single sided with no
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special or critical parts required.
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<h1>Updates:</h1>
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September 2009<br>
|
|
The zero of the meter tends to drift with changes in the battery
|
|
voltage. Several builders have emailed me with modifications to
|
|
use a low dropout regulator to keep the voltage more constant. Since my
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|
unit runs on 4 nicad cells, there is not enough headroom for a 5volt low
|
|
dropout
|
|
regulator. The charged voltage of my nicad pack is 5.6volts, but most of
|
|
the packs useful life is down around 4.8volts. I added a
|
|
15 ohm 1/2w resistor in series from the battery pack and a 4.7volt 1
|
|
watt zener to ground. This modification really helps keep the readings
|
|
more stable as the
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|
battery discharges. With the lower supply voltage, I had an issue with
|
|
driving the meter to full scale. I ended up reducing R17 from 10k down
|
|
to 4k7.
|
|
The latest success story using the ESR meter was finding an open
|
|
330uF/25v cap on the output of a wall wart supply used with a wireless
|
|
router. Replacing
|
|
the $0.25 part saved me buying a $100.00 router.
|
|
|
|
<p align="CENTER"><img src="Capacitor%20ESR%20Tester_files/spectbar.gif" height="7" width="573"></p>
|
|
<a href="http://web.archive.org/web/20120406084010/http://members.shaw.ca/swstuff/index.htm">
|
|
<img src="Capacitor%20ESR%20Tester_files/home.jpg" alt="home.jpg" border="0" height="29" width="90">
|
|
Back to Lawrence's Software Stuff Page</a>
|
|
</strong>
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</strong></body></html>
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