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Principles
Modules
use a blue 0.22uF/250V (marked 22E4) or 0.68uF/250V (marked .68K) to drop the incoming
power which is then rectified and stabilized to usually -12 or -15V. These caps must
be changed to half their value and twice the voltage. So replace a 0.22uF/250 with
0.1uF/400 or 600V. Alternatively, one can connect an identical cap in series with
the original - which is electrically equivalent. Use polyester caps. Never
electrolytic caps.
Most modules uses a
10-22 Ohm 1/2W resistor in series with this capacitor in order to reduce the current when
turning on power to the module. Change this one to twice the value and twice the power. In
most case it will work fine without this modification but it could increase the MTBF (Mean
Time Between Failure). Alternatively you could accomplish this by either replacing
the resistor or adding a similar one in series.
Some modules like
the WS467 have a voltage divider consisting of two capacitors. The value of the second
smaller one, going to logical ground, should not be changed. You should instead replace it
with the same value and with a 400-600V type. In the case of WS467, this is the 0.1uF. The
first and bigger capacitor should be changed to half of the value but 400- 600V. This
capacitor is also usually blue.
Almost all modules
uses a serial capacitor to insulate the receive/ transmit circuit from the main supply and
to adapt the impedance to the electrical power network. It is very difficult to tell what
is the actual impedance of your electrical network (your antenna!) at 120 kHz . It will
change with whatever you turn on or plug in and even your cable types might affect it.
However, statistically and from a practical point of view, consider it to be twice as high
on 220V as on 110V if you have the same power (kW) consumption. Therefore, change this
receive/ transmit capacitor to 400-600V and just to be able to physically fit it at the
same place, half of the value. Even this one is usually also blue.
Most modules use a
330k resistor coming from the incoming supply to two diodes to generate the zero crossing
pulse. This value is not very critical. However due to the voltage across this resistor I
recommend a physically bigger resistor like a 330k-560k 1/2W.
Appliance
modules and universal modules use a 110V cam relay. To reduce the voltage, connect a 100
Ohm/1W resistor in series with the coil. Universal modules need 33Ohm/2w resistors.
Connect the resistor by cutting or desoldering one of the cam wires and then solder the
resistor between the cuts.
MOV means Metal
Oxide Varistors and are used as over voltage suppressors. Over voltages can be caused by
lightning, switching of inductive loads, or even high tension cables falling down on the
distribution cables carrying the main supply of 110-240V. The size of a MOV usually
indicates it's power dissipation capacity which normally corresponds to it's rating in kA,
kilo (1000) Amperes, during a very short period. Remember, Power = Voltage * Current. Use
the biggest MOV that will fit the pcb (Printed Circuit Board). For 220V use a 250V RMS
MOV. If you have 230V or 240V use a 260 or 275V RMS MOV.If a module has a MOV, change the
voltage to 400v (250V RMS)
Use this small Excel calculator to generate a bill of materials
for modifications. For each module type, enter # of modules to modify. Calculates total
number of components, sorted by type.
A Tip for testing
credit: Guy
Lavoie - lavoieg@netcom.ca from an article in HTI.
A module being tested without the dial contacts is set to
code M13. So just connect your module for testing (being extra careful with an exposed
line voltage circuit board) and then set your test code transmitter to code M and send 13
ON and 13 OFF commands.
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