TEC-06 Battery Capacity Tester 16W Electronic Load for 9V Block NIMH Evaluation

[Kiriakos GR]

Today I am going to report a weird detail, relative to TEC-06 Ver 6.4 soldering.

I did discover at both of my units, the support tabs of the rotary encoder as Not Soldered.

My second find this is that one rotary encoder, this was lose from it base (as this to was crashed prior soldering).
Two of four support tabs they shown damage, and they was not holding the base tight enough.

I did remove the rotary encoder from the PCB, I did try to repair it by restoring support tabs clamping force, but this were damaged.

I had another rotary encoder in stock, but I had no memory of it actual specifications, it proved that it is not an 100% compatible replacement.
It different stepping confuses the micro controller,  rotation direction seems as reversed, but it does adjust everything if I rotate it in slow motion.

Long story in short, I did search due Aliexpress all Chinese villages,  and I did find identical stock, and ordered two of these.
At a minimal damage for my wallet of 2.80 € shipped.

The one million dollars question, this is of why the factory does not solder properly the rotary encoder ?   
They do it all the time, I did spot a photograph from Amazon, TEC-06 Ver 6.4 rotary encoder support tabs these not soldered.

From ALPS (Japan) I learned that soldering it should be performed with care, by not exceeding 260C.
I did solder properly my TEC-06 (No 1), and for my TEC-06 (No 2) this is now usable but not perfect, as soon the original spare parts arrive in Greece, the normal functionality this will return back too.

My advice for the brave ones, you should solder the support tabs.
Especially when this PCB it is going to be mounted with screws over a steady surface.

[Kiriakos GR]

Today I was after verifying actual power consumption of TEC-06, so to decide regarding the choice of appropriate wire in AWG, along of the length of my DIY USB 2.0 to USB 2.0 extension cable.

TEC-06 with 5.1V DC supply this require 68.5mA.
DC current of 68.5mA does not change even if TEC-06 this is at stopped and or running mode.

Power consumption increases further only after activation of the DC fan.
Total circuit DC current this now measured at 264mA.
264mA minus 68.5mA = 195.5mA

195.5mA minus 180mA DC fan specification = 15mA for the DC Fan control circuit.   

In order to perform this verification I did make a DIY cable with Male-USB Micro to Female USB Micro, 20Cm long wires of 18 AWG.
Then I connected my test-leads, at my Agilent U1272A DMM at 10A input, for a minimal loss due shunt resistance.

The use of mA DMM input instead, this will introduce significant voltage drop at TEC-06 voltage supply.
Under an such test-leads connection, DC current will fall at 240mA (TEC-06) documented specification, but actual input voltage this will be 4.5V

This breakdown of how many mA they are used due the circuit, and from the DC fan, it did load me with confidence! 

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TEC-06 Micro controller Unit - MCU
Both of my fresh units,  they use software version U.635

The MCU works stable most of the times, but it is sensitive when they are issues with the stability of the power supply.
No matter if you are using a computer USB port, or an dedicated DC power supply, you should look after your cables so them to not move.
Even a poor connection of the wall block, power supply plug to Mains (120~240 ACV), this will cause MCU operation issues.

Therefore about TEC-06, this it should be mounted over a stable metallic project box.
The incoming USB Micro B cable, this must some how be secured against accidental movement.
Battery capacity tests, these take several Hours to finish, it is then wise, TEC-06 along the battery under test, both to be placed away from you, and in one secure corner at your workbench.

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Proper selection of enclosure / project box for the TEC-06

Shunda Electronic this designed TEC-06 as one unit which this will be installed in to a battery testing laboratory.
An number of such units they will be mounted over a metallic aluminum plate, incoming cables will be also secured and unmovable.
Such a setup this is inconvenient for hobbyist and or for a small workshop.   
   
After burning my brain-cells for many days, I did discover accidentally, the ideal project box for both of my TEC-06.   
As soon I receive my ordered parts, then I will be able to finalize my project. 
 

[Kiriakos GR]

Today I did activate my new industrial USB 2.0 to TTL converter, Model UTS-T01 this has CH343G chip.

Driver date: 3/2025
First successful test at my Win 7 Pro 64bit Workstation.
Second successful test at my Win XP 32bit Workstation.

In both tests:
Bits per second 128000
Flow control: Hardware

As load test, I am using Mode2 and my Kenwood bench top, power supply (35V 10A). 

I did make two fresh USB 2.0 Male to USB Female extension cables,  2x28AWG + 2x24AWG, at two lengths of 1m and 1.80m.
With my USB to TTL converter, this be powered due PC USB port, I have 2.5% acceptable voltage loss.
For example: I am measuring DC voltage after the TTL converter.
TEC-06 with DC Fan off = 5,009V
TEC-06 with DC fan active = 4,854V  ( I did run two hours test as verification).

I am now finalizing my setup of communication cables,  I am extremely happy because everything when as planned.   

[Andrew-88]

I bet that the magic at this unusual project box, this is it inner tray and it shape. 

Neither AI this could think of that.