Modifying the DCC6 Dummy Battery Box to Display Battery Status

 

The standard DCC6 dummy battery box allows external mains powered adaptors or external lithium-ion batteries to be used with the FZ100, FZ150, Fz80/82 cameras.

When used with the original mains power supply then the battery status is largely irrelevant. However, if you have used an external 8.4v Lithium-ion battery pack then it is important to know what cahrge is remaining in the battery.

 

The modification here performs that purpose.

 

 

 

 

 

 

 

 

The first stage is to open the battery box.

 

Do this by inserting a sharp blade in-between the hard plastic base plate and the softer plastic cover.

 

Work the blade down into the opposite corner to split the ultrasonically welded seam.

 

 

 

 

 

 

 

 

 

 

 

Cut down to the bottom corner on both sides of the battery box.

 

 

 

 

 

 

 

 

 

Remove any "hot-melt" glue from around the PCB

 

 

 

 

 

 

 

 

 

To complete the modification a 1/8w 10K resistor is soldered from the "T" pad to the negative lead connection pad (black wire).

 

Once that is done re-assemble the box and apply a little drop of "super-glue along the 3 edges. Capillary action will spread the glue along the seams. Wipe off any excess before it dries.

 

 

 

 

 

 

 

 

 

 

Now when this battery box is used it will display the current charge status of the external lithium-ion battery

USB-C Power Delivery Adaptor for Digital Camera External Power Supply

 

Using a ZY12PDN PCB available on Ebay UK or Amazon.com  ( https://amzn.to/37GCuPK ) It is possible to build a USB PD unit to externally power your 8.4v digital camera.

 

 

 

This tiny module provides a means of programming the Power Delivery voltage from the USB-C host device.

 

It can provide 5v/9v/12v/15v and 19v of voltage with a maximum power of 100W (this will also depend upon the capability of the Host PD device)

 

The push button is used to set the output voltage. Each depress of the button cycles through the voltages.

 

It can also be programmed to negotiate a fixed voltage output.

As this unit will deliver 9V at up to 5A (with a suitable host) it can be used to provide the basis of an 8.4volt external power supply if a silicon diode is inserted in the positive output terminal of the device.

This diode will nominally drop 0.6v at typical currents up to 3A.

I chose the 1N5400 as it is capable of 3A continuous current. It would be possible to use a 1N4000 series as in most cases the peak current does not exceed 1.5A with many digital cameras.

 

 

 

 

This is the completed unit with details of how the 1N5400 diode is connected in the positive output lead of the unit.

 

The box that I used is from Amazon. https://amzn.to/37DMlpy

The box needs to be filed on the input side to accommodate the USB-C plug.

 

The PCB is held in place using double side adhesive pad. The output lead is wired to either a 5.5mm x 2.1mm or 4.8mm x 1.7mm plug depending upon the type of socket on the dummy battery box.

the 1N5400 diode https://amzn.to/2N3yzEW

 

 

 

 

 

 

 

 

With the suggested plastic case file out one side so that a USB-C plug fits through the aperture.

 

 

 

 

 

 

 

 

 

The PCB is held in place by thick foam based double sided tape

To program this unit to a set output voltage of 9v first disconnect the unit from any power source.

Press and hold the push button down and connect the PD Host.

The LED will flash all colours, release the button and then cycle through the voltages until you reach the one that you require.

You can check the output with a voltmeter or observe the colour of the LED.

For 5V it is RED

for 9V it is GREEN

for 12V it is CYAN

The programming is voltage based and has these steps: 5V, 8-10V, 11-13V, 14-16V, 18-20V, maximum voltage, auto trigger.

By adding a 8.4v lithium ion battery in parallel with the output from the unit (after the series diode) it provides addition current support if needed and also a backup power source if the Host power-bank becomes depleted. At this point this lithium ion battery continues to provide power to the camera. The power-bank can be then exchanged.

If the lithium ion battery becomes partially depleted it will be recharged once this unit is reconnected to the USB-C host again. The usual over voltage/overcurrent and over discharge protection all being satisfied by the battery management board within the lithium ion battery.

 

 

 

 

 

 

 

 

 

 

An illustration of the ZY12PD board with the series silicon diode and the lithium ion backup battery installed in a small plastic case.

 

 

 

 

In the latest upgrade of this idea I have included a LED Voltmeter module to draw a slight amount of current from the Host Power Bank.

This 30mA of current is enough to prevent the power bank from going into the sleep mode if there is no load detected.

This is a useful feature as with many cameras going into standby mode this in turn would cause the power bank to go into sleep mode.

It would then be necessary to unplug the ZY12 unit in to wake up the power bank and begin the voltage negotiation sequence again.

 

 

To prevent the onboard lithium-ion battery powering the LED voltmeter when the Host power bank is disconnected it is necessary to wire to voltmeter to the +/- outputs of the ZY12 board.

The in series diode prevents the voltage from going to the LED voltmeter module.

 

I chose a module which drew sufficient current to keep the host power bank, that I normally use, alive but would have minimal effect on the total output capacity from the unit. Some power banks may require a higher standing current to keep them alive. I suggest increasing the current in steps of about 30mA by adding a parallel resistance of 330 ohm if your power bank still shuts down with this module alone.

If the addition 330 ohm doesn't work try a 150 ohm which would add 60mA to the standby current.

 

the unit that I used https://amzn.to/2sXLm4X

 

 

 

 

 

 

 

With just the display wired across the output the standby current taken from the power bank was 20mA

 

 

 

 

 

 

Adding a 390 ohm resistor in parallel with the LED voltmeter increased the standby current to 44mA which was enough to prevent all of power banks that I currently use.

The sequence of connection of the unit is important as the serial data communication has to take place to set the negotiated voltage from the host PD device.

When the unit is plugged into the Host PD device the green led light will illuminate denoting successful connection.

If there is no load on the power bank through this unit the power bank may go into a shut down mode.

If you press the power on button to "wake up" the unit it may not correctly communicate with the ZY12PD board and the LED will flash a white/cyan colour.

Unplug the device and reconnect it to correctly restore communication.