Testing for current draw

Feb 17, 2006
5,274
Lancer 27PS MCB Camp Pendleton KF6BL
Here I go again. This time it is garden type solar lights. I have a few of them scattered about my yard. They work well, yet, there seems to be 2 that just do not want to stay on all night. So I decided to see if I can figure out what is going on.

The first thing I did was charge the battery to see if the charging circuit was working. The 1.2v battery tested at 1.355v with load. So that is good. Next, how much current is the light drawing?

Well, that is going to be a trick. How to see the current with my meter without taking the whole solar light fixture apart. Got it!

I have some 1/2" wide copper adhesive tape. I cut off two pieces about 3/4" long. Put them together to cut out tabs. Then I took off the backing and fixed both pieces to an old business card. Trimmed all the edges.

upload_2018-2-5_21-34-40.jpeg


Now that I have both sides with copper, I can insert this into the battery well between the battery (+) tab and the battery. I have to be careful because this could actually be used as a capacitor.

Once it is in the battery well, the voltage and current are blocked because of the insulator. So the light will not turn on. Now I can connect the meter.

upload_2018-2-5_21-38-33.jpeg


As you can see, the light is drawing 37ma. With this setup, I can also check other things that use batteries as long as one side of the connection is accessible. For this test, the light stayed on for about 6 hours. The battery is 1350mah 1.2v NiMH. So there is something in the circuit that is drawing too much. By the time the light goes out, the battery is around .9v. Maybe a bigger battery. 300mah battery last only 4 hours.

So, thought I would share.
 
Jun 6, 2006
6,990
currently boatless wishing Harrington Harbor North, MD
I'm thinking corrosion in the battery box or the solar cells are not charging the batteries well. FWIW
 
Feb 17, 2006
5,274
Lancer 27PS MCB Camp Pendleton KF6BL
Bill, this was more about developing a tool to test current flow, than the actual reason why the light was not working well. But the battery well is clean. The lights are not that old. I believe it to be something about the design or even the LED itself.
 
Oct 19, 2017
7,980
O'Day Mariner 19 Littleton, NH
Could the battery simply be defective? I love your creative instrumentation. The capacitance consideration of your manufactured prob interface is interesting. By careful, I assume you mean to try and keep it from a static charge buildup? What is your solution? Would you need to ground it out just before connecting it, to discharge the static? Would the charge not build back up as it stayed connected through the test?

- Will (Dragonfly)