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John Wiltrout's Blog A New Approach to a Bench Top Ammeter
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  • Author Author: jw0752
  • Date Created: 29 Sep 2017 1:18 AM Date Created
  • Views 1214 views
  • Likes 8 likes
  • Comments 16 comments
  • chinese_kits
  • bench_top_ammeter
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A New Approach to a Bench Top Ammeter

jw0752
jw0752
29 Sep 2017

     When I first found this Chinese Ammeter kit I bought it, as at $4.62 and free shipping it was a no brainer.

 

https://www.banggood.com/ICL7107-Digital-Ammeter-DIY-Kit-Electronic-Learning-Kit-p-977902.html?rmmds=search

 

image

 

At +/- 1 mA resolution the specifications were very acceptable to the level of precision that I usually need. I love these inexpensive kits, not only for the low $ that I have invested, but also for the challenge that is introduced by their low cost. Instructions are often wrong, poorly translated, and occasionally the circuit is in need of redesign. My first challenge with this one was the instructions which I was able to download from the sales site. While labeled as English they in fact were a hybrid between English and Portuguese. While I can not speak Portuguese, my second language Spanish, allows me to read it with an acceptable degree of understanding. The need for detailed understanding however was not an issue with this kit. The screen print on the circuit board was well done and identified all the components properly. In fact I rather regretted printing the entire assembly manual as the step by step illustrations used up a lot of my green printer ink in the 11 pages of illustrations for placing each individual component.

 

image

This was the first page of the instructions

 

The meter was fun and easy to assemble with only one final mV calibration between pins 35 and 36 of the main IC necessary. The circuit is powered by a 5 volt source and will output a reading of +/- 0 to 2 Amps with the supplied 0.1 Shunt Resistor. I noticed that there were solder pads that can be bridged to move the decimal point and one entry in the manual indicated that the meter was also being marketed to read 0-20 Amps and 0-200 Amps. Apparently a 0.01 ohm shunt will give a 0-20 Amp range and a 0.001 Ohm shunt will yield a 0-200 Amp Range.

 

I thought briefly about making the circuit multi-range by switching in the appropriate shunt resistors but some quick experiments showed that due to lead resistance and switch contact resistance I would not be able to obtain the needed accuracy.

 

I hooked the raw finished meter up and ran some trial tests to compare it against my other moderately accurate test equipment. It worked very well displaying one more decimal place than I had on the Fluke 177 and it seemed to be consistent over the 0 to 2000 mA range. Many of my little experiments utilize a mA meter and I suddenly had a memory flash from the past of the meters we used to use in High School Physics Class when we played with electricity.

 

 

 

                                                                                                                     image

 

Why not make a modernized bench digital Ammeter in the same spirit as this moldy oldie? I looked through the selection of salvage cases from various dental equipment and found one that used to be part of a monitor for a Sterilizer. It was perfect except that it was constructed of 1.5 mm thick steel. An hour and a half later with lots of drilling, sawing and filing I had finally cut the 4 X 7 cm hole needed for the meter. The holes for the binding post were easy and I had the meter mounted and soldered to the binding posts.

 

My next decision was how was I going to power the meter. There was lots of room inside the case. I think they call meters like this lunch boxes for all the extra room. While it would have been very easy to put a small AC to 5 volt DC power supply into it I decided that I didn't want to add the need for another power wire to my experimental setups. Since the unit runs on 5 volts my attention was pulled to a small cell phone auxiliary charging battery that I had on the bench charging my cell phone.

 

image

 

I checked the mA hour rating on the battery and it said 2200 mA hours. My guess is that this is a gross exaggeration but even if it is half that amount in reality it should power the 35 mA draw of the meter for 30 hours which is more than adequate for my convenience. Further more all I have to do to recharge the batter is plug it into a telephone re-charger. Here are a few pictures to show you the final product.

 

image

 

image

 

Here are a couple pictures of the inside.

 

image

 

image

 

Finally we have the meter monitoring a current through a power resistor:

 

image

 

Not counting my time (hint: not worth much at this stage of life) the meter cost $12.00 including the battery. I had a good time putting it together and I anticipate the pleasure of using it in my next experimental setup requiring the monitoring of a current.

 

John

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Top Comments

  • jw0752
    jw0752 over 7 years ago in reply to Jan Cumps +4
    Having a job that one loves is as good as it gets! It is also a pretty good indication of success. John
  • Jan Cumps
    Jan Cumps over 7 years ago +3
    my time (hint: not worth much at this stage of life) Your time is priceless and you spent it well
  • jw0752
    jw0752 over 7 years ago in reply to Jan Cumps +3
    Thanks Jan, I used to get paid in $ and now I get paid in Fun. John
  • shabaz
    shabaz over 7 years ago in reply to jw0752

    Hi John,

     

    Neat trick with the range setting resistors! It was quite pleasing to see how that all worked out and the nice values chosen to make the parallel combination equal to (0.1-0.01).

    It is a beautifully finished project as usual : )

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  • jw0752
    jw0752 over 7 years ago

    As mentioned in my previous post 12 days ago I decided to build a one channel 30 volt Power supply and incorporate the now dual range Ammeter as an auxiliary test option. I will not go through all the process for building the new piece of test equipment as you have endured enough of my power supplies. Here is the finished product. In the two pictures below I am running an efficiency comparison between a standard linear 7805 voltage regulator and a Recom R785.0-1.0. Here is the 7805 in action:

     

    image

     

    From the display we can see that the input to the 7805 is 8.5 volts at 350 mA for a total power input of 2.89 Watts. The auxiliary ammeter is reading the current on the 5 volt output into a 14 ohm load. This was perhaps a bad choice as it is also displaying 350 mA which may be confusing. However 350 mA at 5 volts is only 1.74 Watts and if we divide this by the input wattage we get about 60% efficiency. The extra 40%, of course if being shed as heat in the 7805.

     

    image

     

    Now we have the R785.0-1.0 DC to DC converter in place of the 7805. Since we still have 5 volts output into the 14 ohm load we still have a 350 mA current displayed on the output. Notice however that the input current has dropped to 210 mA. At 8.5 volts this translates to 1.79 Watts and if we divide this into the output wattage of 1.75 watts the result is 98% efficiency. Here is a slightly better picture of the new unit:

     

    image

     

    John

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  • jw0752
    jw0752 over 7 years ago

    After having a few days to think about it I realized that I was approaching the idea of expanding the ammeter to a dual range version all wrong. Sometimes I get a wrong idea in my head and it takes a while to see past it. In this case I was envisioning having to switch different shunts into the circuit in order to have a dual range device. Yesterday the light in my head finally flickers and brightened a bit so I realized that the shunt should be a fixed 2 stage voltage divider and that I only need switch the input of the meters ADC from one point on the shunt to another while also switching the display decimal point one place. Here is a schematic for what I decided to do:

     

    image

     

    Now in theory the resistors are the values that are printed on them and everything turns out pretty but this seldom happens, at least in my world. In this case the theory only got me to the point where one scale was off from the other by about 10 percent. If I had a reading on 2 amps on the 2 amp scale the 20 amp scale would read 1.8 amps. After an hour of adding various resistors to the Trim resistor I finally had both scales on the same page. Here a re a couple pictures of the display reading 318 mA

     

    image

    2 Amp Scale

     

    image

     

    20 Amp Scale

     

    Here is a picture showing the messy shunt with the extra 2 trim resistors across the 0.1 ohm shunt.

     

    image

     

    Note that the input to the ADC starts with a series 1 M resistor. At least by switching the ADC and not shunts the resistance of the switch contacts are irrelevant.

     

    This is a different unit from the one that I built above in the black case. I am still trying to decide if I am going to make that one into a dual range as I did not plan for a range switch and there isn't a really good place to put one. Perhaps I will have to wait for the lights in the old head to flicker on again.

     

    Last picture shows the whole raw ammeter and the switch. I am currently planning on building a one channel 30 volt bench supply with an auxiliary ammeter and this one will get used in that build.

     

    image

     

    John

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  • DAB
    DAB over 7 years ago in reply to jw0752

    More importantly you are learning while having fun.  The best of all worlds.

     

     

     

    DAB

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  • balearicdynamics
    balearicdynamics over 7 years ago in reply to jw0752

    Hey John, just a bit of effort and some advice and you can join satisfaction with $. It's the worth - not too much $ - as it is a more satisfactory certification of your value added to the makers, experimenters and creators community. Trust me image

     

    Enrico

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