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Set Up and Operation
1.5.3.2
MODIFYING OR REMOVING THE INTERNAL BRAKING RESISTOR
The type of braking resistor installed on the heat sink allows a maximum continuous
dissipation of 50W, but can tolerate many times this power level for short periods. The
value installed as standard only allows a maximum dissipation of 35W owing to its
high resistance. If the user wishes to change the resistor to a lower value or remove
the resistor completely as they are using an external resistor, then they should follow
the procedure given below.
? Follow the procedure given in Section 1.5.2 “Accessing The System” for
accessing the unit.
? De-solder or cut the wires to J7 and J8. This can be done from the top of the PCB.
? Undo the screws attaching the resistor to the heat sink and remove the resistor
and its wiring.
? If not fitting a new resistor, proceed to the last step.
? Make up a wiring assembly for the new resistor with similar lead lengths and the
terminals protected with heat shrink sleeving. Ensure the wire has sufficient
current and voltage rating (600V).
? Apply a thin, even coating of thermally conductive heat sink compound (e.g.,
Dow-Corning 340) to the back of the resistor.
? Fit the resistor to the heat sink and solder the wires into J7 and J8. Ensure the
leads are cropped so that the maximum length of lead protruding below the PCB
is 4 mm.
? Once the modification is complete, install the lid ensuring all the screws are
replaced.
Note that if the user fits a lower value of internal resistor to allow higher transient
dissipation, then the user's software must ensure adequate thermal protection for the
resistor. Failure to do so can cause the resistor to rupture. Consult the manufacturers
data sheet carefully.
1.5.3.3
BYPASSING THE PFC
If the user does not require the use of the active Power Factor Correction, all the user
needs to do is not fire the PFC switch. The system will still benefit from the PFC
inductor acting to smooth the input current when the rectifier is charging the DC bus
capacitors. However, the PFC diode will remain in circuit. This will incur additional
unnecessary loss. Provision has therefore been made to bypass the PFC in two
different ways. Alternatively, the user could feed in an external DC supply using the
auxiliary DC input (see Section 1.2.2 “Making Power Connections” ). The
procedures for bypassing the PFC is described below:
Keeping the PFC inductor in circuit:
? Follow the procedure given in Section 1.5.2 “Accessing The System” for
accessing the unit.
? De-solder the wire of the large toroidal inductor marked as L2 (2) near the
left-hand DC bus capacitor C4. This can be done from the top of the PCB.
? Solder the L2 wire into pad J4 ensuring that the maximum length of lead
protruding below the PCB is 4 mm.
? If required, replace the input fuse with a 6-7A part of the same type (Time Lag,
High Breaking Capacity and 250V or greater voltage rating).
? Once the modification is complete, install the lid ensuring all the screws are
replaced.
? Note that the maximum continuous limit on input current increases to 6A (RMS)
limited by the loss in the PFC inductor.
? 2003 Microchip Technology Inc.
DS70096A-page 33
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