Life Science Group

PowerPac™ Universal
Power Supply

Service Manual

Part Number 100-2754C BP-020193

 PROPRIETARY NOTICE

Information contained in this manual is copyrighted by Bio-Rad Laboratories, Inc. None of the contents may be
reproduced in full or in part by any person without the prior written approval of Bio-Rad Laboratories, Inc. This
manual is intended to provide information to assist the qualified field or instrument service technician to repair,
maintain, and order replace parts for the instrument supplied. Every reasonable effort has been made to keep
the information in this manual current and accurate as of the date of publication or revision. However, no guar-
antee is given or implied that the manual is error-free or accurate about any specification.

Copyright 2003 - 2008 by Bio-Rad Laboratories, Incorporated. All rights reserved.

Bio-Rad Laboratories Inc, Life Science Group
2000 Alfred Nobel Drive
Hercules, California 94547
Telephone: 1-800-424-6723

100-2754C 10/08 i
 About this manual This document is part of Life Science Group’s commitment to provide
you, the service professional, with adequate information to effectively
support Bio-Rad instruments. Additional copies of this service document
may be ordered using part number 100-2754.

We welcome and appreciate any suggestions you may have to improve

our service documentation. Please address your comments or sugges-
tions to:

Technical Editor, Global Service Support Dept.

Bio-Rad Laboratories, Life Science Group
2000 Alfred Nobel Drive
Hercules, CA 94547
FAX Number: 510 741-6929

ii 100-2754C 10/08
 Revision Control List

Document: PowerPac™ Universal Power Supply

Part Number: 100-2754
Date Issued: October, 2008

Each page of this manual has the catalog number, revision level and revision date. Subsequent revisions to the
manual will be indicated by changes to the revision level and revision date for the entire manual. A summary of
changes for all revisions is listed in the following table.

Page Business Changed

Revision Description Date
Number Process By
A Release at Revision A N/A M.Guerra 10/03
B 6-1 Updated part number BP-015267 M.Guerra 11/07
6-2 thru 6-4 Updated part numbers
7-1 Updated part number
8-2 thru 8-4 Updated Troubleshooting Guide information
9-1 thru 9-5 Updated part numbers
C 4-7, 4-8 and Changed Constant Voltage to 195 V on Table BP-020193 M.Guerra 10/08
4-11 4-1 and 4-2, step 1. Also on the Service
Repair and Test Certification, at 80 Ohms

100-2754C 10/08 iii

 Table of Contents

Page
Section 1. Introduction
1.1 General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.2 Service Philosophy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.3 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1.4 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Section 2. System Overview

2.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 PowerPac Universal Catalog Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.4 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.1 Manual Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.4.2 Methods Mode Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5 Electronics Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5.1 Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.5.2 SRAM and Flash RAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.3 Front Panel Switch Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.4 LC Display Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.5 IrDA Port Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.6 Real-Time Clock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.7 Power-Off Sense Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.8 Watchdog Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.5.9 Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5.10 Overvoltage/Overcurrent Protection . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5.11 Leakage Current Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.5.12 Over-Temperature Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6 Power Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.6.1 On/Off Power Control and AC Filter Network . . . . . . . . . . . . . . . . . . . . 2-5
2.6.2 HV AC-DC Rectifier and Capacitor Filter Banks . . . . . . . . . . . . . . . . . . 2-5
2.6.2.1 Main Rectifier and Capacitor Filter Bank . . . . . . . . . . . . . . . . . . . 2-5
2.6.2.2 Low-Power Rectifier and Capacitor Filter Bank . . . . . . . . . . . . . . 2-6
2.6.3 AC Line Autorange Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.4 Dual Main Power Converter Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.6.5 Main PWM Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10
2.6.6 Error Amplifier and Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
2.6.7 Auxiliary DC-DC Converter Network . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
2.6.8 Power Good Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
2.7 Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

100-2754C 10/08 iv
Table of Contents

Page
2.8 Operation with a Personal Computer and PDA . . . . . . . . . . . . . . . . . . . . . . 2-14
2.8.1 Operation with a Personal Computer . . . . . . . . . . . . . . . . . . . . . . . . . 2-14
2.8.2 Operation with a PDA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.9 PowerPac™ Universal Front Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
2.10 PowerPac™ Universal Rear Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.11 Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16
2.12 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Section 3. Installation
3.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Unpacking the PowerPac Universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Setting Up the PowerPac Universal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Connecting the Universal to the Electrophoresis Cell . . . . . . . . . . . . . . . . . . 3-2
3.4.1 Connecting Power Supply/Cell at Constant Voltage . . . . . . . . . . . . . . . 3-2
3.4.2 Connecting Power Supply/Cell at Constant Current . . . . . . . . . . . . . . . 3-3

Section 4. System Checkout

4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Power on Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.4 Rapid Resistance Change Detection/No Load Detection Test . . . . . . . . . . . 4-2
4.4.1 Rapid Resistance Change Detection with RRCd On . . . . . . . . . . . . . . 4-2
4.4.2 Rapid Resistance Change Detection with RRCd Off . . . . . . . . . . . . . . 4-3
4.5 Overload Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.6 Power Failure Detection Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6.1 Power Failure Detection with PFd On . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.6.2 Power Failure Detection with PFd Off . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7 Constant Voltage, Current and Power Test . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.7.1 Constant Voltage, Current, and Power Test at 80 Ohms. . . . . . . . . . . . 4-6
4.7.2 Constant Voltage, Current, and Power Test at 500 Ohms . . . . . . . . . . 4-8

Section 5. Preventative Maintenance

5.1 PowerPac™ Universal Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Overnight Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.3 Long-term Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.4 PowerPac™ Universal Preventative Maintenance . . . . . . . . . . . . . . . . 5-1

v 100-2754C 10/08
 Table of Contents

Page
Section 6. Removal and Replacement
6.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.2 Replacement / Adjustment Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3 Removal and Replacement Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.2 Front Panel/Top Cover Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6.3.3 Main Board Removal (800-8686-01) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.4 Temperature Sensor Removal (800-8697) . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.5 Firmware Removal (800-8605) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.6 Fan Assembly Removal (800-7368) . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.7 Display Board Removal (800-8693-01) . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.8 Fuse Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

Section 7. Adjustment and Calibration

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.2 Adjusting the Screen Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3 PowerPac Universal Power Supply Calibration . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3.1 Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3.2 Installing the PowerPac Remote Software . . . . . . . . . . . . . . . . . . . . . . 7-1
7.3.3 Enabling the Maintenance Command . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
7.3.4 Calibrating The PowerPac Universal . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
7.4 Burn-In Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
7.5 Set Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6

Section 8. Troubleshooting
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Troubleshooting the PowerPac™ Universal . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.1 Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2.2 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.2.3 Test Point List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4

Section 9. Parts Information

9.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.2 Parts Orders - US Domestic Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.3 Parts Orders - International Subsidiaries . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.4 Returning Defective Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1
9.5 Recommended Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.6 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4

100-2754C 10/08 vi
Table of Contents

Page
9.7 Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5

Section 10. Drawings

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.1 Power Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3 Assembly Drawings and Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3.1 Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.3.2 Assembly Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1

Section 11. Appendix

11.1 PowerPac Data Transfer Software . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.1.1 Installing the Data Transfer Software onto a PC . . . . . . . . . . . . . . . . 11-1
11.1.2 Installing the Remote Software onto a PC . . . . . . . . . . . . . . . . . . . . 11-1
11.1.3 Infrared (IR) Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 Maintenance Mode Commands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2.1 Enabling the Maintenance Command . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2.2 Set Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-2
11.2.3 Set Serial Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2.4 Restore Factory Defaults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2.5 Stop Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2.6 Set PFd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
11.2.7 Calibrate Low C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11.2.8 Calibrate High C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4
11.2.9 Use Calibrated C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5

vii 100-2754C 10/08

 Introduction

Section 1
Introduction

1.1 General Information

This manual is the reference to be used for troubleshooting, repair, and maintenance of the PowerPac Univer-
sal power supply. It is intended to be used by trained technicians and engineers familiar with safety precautions
relative to working with hazardous voltages. The procedures in this manual assume that the reader is familiar
with the operation of the PowerPac Universal power supply. Complete operating instructions are contained in
the PowerPac Universal power supply instruction manual. Information presented in the instruction manual is
not repeated in this Service Manual unless there is a compelling reason to do so.

1.2 Service Philosophy

This manual is designed to support mail in products. Regional service centers are the first level of service,
where faulty assemblies can be most effectively repaired at a central repair facility. The second level of service
is performed at our factory instrument service facility in Richmond, California, where additional service proce-
dures requiring resources not available at regional service centers are performed.

1.3 Safety
The PowerPac Universal power supply contains hazardous voltages

The following should be observed when servicing this unit:

• When power is required, the unit should be plugged into an outlet with a properly grounded receptacle. The
use of 2-prong plug adapters is not recommended and will void the safety certification of this product.
• The use of extension cords may compromise the safety of the operator and is not recommended.
• Ensure that fuses installed in the unit are of the correct rating.
• Ensure that none of the ventilation openings in the unit are blocked. Excessive heat buildup in the unit may
cause failures.

Note: This Bio-Rad product is designed and certified to meet *EN61010-1 safety standards. Certified
products are safe to use when operated in accordance with the instruction manual. This instrument should not
be modified or altered in any way. Alteration of this instrument will void the warranty, void the EN61010-1 certi-
fication, and create a potential safety hazard. This safety certification does not extend to other equipment or
accessories not EN61010-1 certified, even when connected to this product.

Bio-Rad is not responsible for any injury or damage caused by the use of this instrument for purposes other
than for which it is intended or by modifications of the instrument not performed by Bio-Rad or an authorized
agent.

100-2754C 10/08 1-1

Introduction

1.4 Operating Conditions

• To ensure adequate cooling of the power supply, be sure that there is at least six cm clearance around the
power supply. Do not block the fan vents at the rear of the unit.
• PowerPac™ Universal power supply can be operated at temperatures between 0 to 40°C, with relative
humidity between 0 and 95% non-condensing. Operating the power supply outside these conditions is not
recommended by Bio-Rad and will void the warranty.
• Do not operate the power supply in extreme humidity (>95%) or where condensation can short the internal
electrical circuits of the power supply.
• Always connect the power supply to a three-prong, grounded AC outlet, using the three-prong AC power
cord provided with the power supply.
• Never connect a high voltage lead to earth ground. This defeats the floating isolation of the power supply
and exposes the user to potentially lethal high voltages.
• When taking the PowerPac™ Universal power supply into a cold room, the unit can be operated immedi-
ately. However, when removing the unit from the cold room, allow the unit to equilibrate to room temperature
for a minimum of two hours before operating.
• Bio-Rad electrophoresis cells have molded two-prong plugs that are inserted into the power supply’s high
voltage output jacks. The plugs have been EN61010 certified for safety compliance for use with the Power-
Pac™ Universal. Use of other plugs or bananas jacks is done at the operator’s own risk and is not recom-
mended by Bio-Rad. When inserting and removing the molded two-prongs plug, always grasp the plug by
the molded support at the rear of the plug. Do not grasp the individual prong or metallic ends.

1.5 Conventions
The following conventions are used throughout this manual:
• Left and right sides of the unit are as viewed from the front, operator’s position, unless otherwise stated.
• Dimensions are in inches, unless otherwise stated.

1-2 100-2754C 10/08

 System Overview

Section 2
System Overview

2.1 Introduction
This section of the manual provides an overview of the PowerPac™ Universal power supply including theory of
operation and circuit description.

2.2 Product Description

The PowerPac™ Universal is a 500W electrophoresis power supply that employs state-of-the-art microcon-
troller electronics and power conversion networks and output variable power. It is designed to provide constant
voltage, current or power for a wide range of electrophoresis applications, including the Dodeca cells and IEF.

The PowerPac has the following features:

• Constant voltage, constant current, or constant power operation with automatic crossover.
• LCD screen displays all running parameters at once.
• Programmable methods with up to nine steps.
• Storage capability for up to nine user defined methods.
• Continuous, hour and volt-hour time modes.
• Pause run editing.
• Safety features: no-load, short circuit, rapid resistance change, ground leak, and system overheating.
• Automatic run completion after an AC power failure.
• Adjustable LCD display contrast.
• EN61010 international safety certification.
• Input power 100-120/220-240 VAC, 50/60 Hz, auto-switching.
• Four output terminals.
• Stackable case with adjustable viewing angle via flip down legs.
• IR port, for transmitting data to a personal computer or PDA (Personal Digital Assistant).
• Data Transfer Software (DTS) for data file management on a PDA and PC (Optional).

2.3 PowerPac Universal Catalog Number

The PowerPac Universal can be purchased under the following catalog number.

Product Catalog Number

PowerPac Universal Power Supply 164-5070

100-2754C 10/08 2-1

System Overview

2.4 Theory of Operation

The PowerPac™ Universal has two operating modes: Manual and Methods.

Figure 2-1: PowerPac™ Universal Power Supply

2.4.1 Manual Mode Operation

The Manual mode allows the user to program and start a single method with a minimum number of key-
strokes. This single step method is not stored in permanent memory; however, the run parameters are kept
in the flash memory until the PowerPac is turn off. This allows repeating the same run without having to re-
enter the parameters and values.

2.4.2 Methods Mode Operation

The Methods mode operation is used to create and run single and multi-step methods. In method mode, up to
nine methods, each with up to nine steps may be created or edited. Each of these methods may be transferred
to or from a PDA, through the PowerPac Universal IR port.

2.5 Electronics Description

2.5.1 Microcontroller
The U11 is a microcontroller of the 8051 family. Its clock is generated by the internal clock circuitry in con-
junction with X1 at a frequency of 18.432 MHz. U12, a power supervisor chip, provides the reset signal to
the processor, also prevents the A/D converter from turning on the power converter at power-up, or when the
5V generated on the board drops 5%. The 16 bits od address space is taken from the multiplexed data bus
by U16. A GAL (U18) decodes addresses for the devices contained in U11. If an update to the code operat-
ing the supply is required, U11 must be replaced.

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2.5.2 SRAM and Flash RAM

The U17 is static RAM to be used for program operations. U24 is used to store operational parameters,
operator settings, and run information that is used in the event of AC power failure.

2.5.3 Front Panel Switch Interface

The U27 and U29 provide ports to read the switches, reset the LCD, enable the power converter, and reset
the watchdog timer. U28 are open-collector gates that provide the signals to read the switches. A write to
U27 sets one of the four open-collectors gates low, and then the processor reads the state of the switch con-
tacts through U29. A switch being pressed will pull one of the inputs to U29 low, which specifies which switch
was pressed.

2.5.4 LC Display Interface

The U20 and U35 form bi-directional port to the LCD. U20 is used to read the status from the display, and
U35 is used to send data to be displayed on the LCD. U33 is used to generated the “E” signal that gates
data in both directions. The pins of J6 are interleaved in that the odd pins connected to the LC display, and
the even pins connected to the switches and the IrDA port. The LCD contrast signal is produced by the cir-
cuit at location A5-6 (See schematics E-8686). A pulse-width-modulated signal is produced by the processor
that is inverted by U16. This signal is then averaged by R63 and C13. This voltage is then amplified and
inverted by U7 to produce the negative voltage required by the LCD. This voltage should be about -7V, and
is adjustable by the user through the “Setup” menu. Values allowed are between 70 and 110. This range
should allow the user to set an appropriate contrast for viewing the LCD.

2.5.5 IrDA Port Interface

The IrDA port interface is located at B7-8 (See schematics E-8686). This port operates through the serial
port on U11, the microprocessor. U19 provides a method of controlling the settings of U21, which encodes
and decodes the pulses used to communicate via IrDA. Baud rate generation is done using X3 and 3.6864
MHz. Baud rates are selected through the A0, A1, and A2 lines (See schematics E-8686) from U19 to U21.
The transceiver for the system is on the Front Panel board, along with the dropping resistor necessary to
limit the current used by the IrLED used to transmit data.

2.5.6 Real-Time Clock

The U31 is a real-time, clock/calendar with battery back-up. When power is off, the battery B1 powers the
clock and keeps it running. CR27 is a dual diode package that allows the power supply to furnish current to
run the clock when the AC is on, and the battery to run the clock when AC is off. Crystal X2, 32.768 KHz
drives the on-chip oscillator.

2.5.7 Power-Off Sense Circuit

The Power-Off Sense circuit senses when AC power has stopped delivering power to the unit. Two optocou-
plers (OC2 and OC3) discharge C97 and C104 with alternating half-cycles. When AC stops, the discharge
also stops, resulting in Q16 being turned on, which pulls PGD low, and alerts the microprocessor that the
+5V supply is about to go away. This triggers the processor to store running parameters and prepare to
restart a run upon resumption of AC power, if the operator has requested that function.

2.5.8 Watchdog Circuit

The U36 is the heart of the watchdog circuit. This circuit is reset everytime the front panel switches are read.
Since this a continuous process, this one-shot is continually reset when the processor is operating normally.
When that stops, Q19 pulls the OVOC (Over Voltage/Over Current) signal low, which turns off the power
converter and prevents an unsafe condition.

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2.5.9 Digital Control

The power converter has its own feedback circuitry to regulate the output voltage. In order to provide the
capacity of the system to run in constant current or constant power mode, digital control is used. U13 is a
digital-to-analog converter that is used to control the output voltage of the converter. The two op-amps in
U25 provides a small amount of gain so that a digital input of 4000 will produce 500 Volts from the con-
verter.This means that there are 8 counts per voltage output, which is more than sufficient to regulate prop-
erly. U26 provides a 5V reference to operate the digital control area. U14 is a four-channel analog-to-digital
converter that provides information on the current and voltage being produced by the converter. It is used in
a differential mode to accurately measure the following things. Channel 0 measures the voltage produced by
the converter, with channel 1 being the reference for the measurement. Channel 2 measures the current,
with channel 3 being its reference. The voltage signal is taken from a node which will have the same voltage
put out to the converter when the system is operating normally. The current signal is taken from an amplified
signal from the current sense resistor, R42. U9 is a differential op-amp that provides a signal that will repre-
sent about 0.618 counts per mA. This means that the maximum current of 2500 mA produces 500 counts on
the analog-to-digital converter. The conversion factor is programmed using a calibration procedure that is
accessible through the maintenance portion of the PDA program.

2.5.10 Overvoltage/Overcurrent Protection

The converter is protected from overvoltage and overcurrent conditions by two circuits. Each of these shuts
the converter down if there is a loss of signal control that produces either condition. Comparator U34 is used
for this purpose. The voltage produced is compared to a reference, and if the voltage exceeds about 540V,
the converter is shut down. The current produced is compared to reference, and if the current exceeds about
2850 mA, the converter is shut down.

2.5.11 Leakage Current Detection

Leakage current is detected by R96 and R97. This produces the signal GNDCURRENT. This signal is ampli-
fied by the circuitry at location C7-8 (see schematics E-8686). If the current exceeds 500µA, a signal is sent
to the processor, and Q18 shuts the converter down.

2.5.12 Over-Temperature Protection

Over-temperature protection is provide by an IC that is placed in the air near the inlet slots in the front of the
unit. If the fan fails or is obstructed, this area will become hot. The IC produces a signal that is 10 mV/ °C
absolute, and when the temperature reaches about 57°C, an overtemperature signal is sent to the proces-
sor, which shuts the converter down, and places a warning signal on the LCD.

2.6 Power Conversion

The circuit elements that make up each of these eight subsystems can be found in the PowerPac Universal
Power Converter schematic E-8686 located in Section 10. There are eight functional circuit areas that make up
the power control area:

• On/Off Power Control and AC Filter Network

• HV AC-DC Rectifier and Capacitor Filter Banks
• AC Line Autorange Control
• Dual Main Power Converter Circuitry
• Main PWM Control Network
• Error Amplifier and Control Network

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 System Overview

• Auxiliary DC-AC Converter Network

• AC Power Good Detector

2.6.1 On/Off Power Control and AC Filter Network

AC power is applied to the PowerPac Universal via a power entry module mounted on the chassis of the
unit. This module also contains two user-replaceable 6.3A fuses (900-7288), one per AC entry point (line
and neutral). Power ON/OFF control is provided by a manual DPST toggle switch S1 mounted on the side of
the PowerPac Universal chassis.

Caution: ALWAYS remove the external AC power plug connector when servicing the PowerPac Universal
circuitry to prevent shock to service personnel should switch S1 be accidentally placed in the ON position
during a service operation

Filtering of common-mode and differential noise levels generated by the high-frequency switching opera-
tions of the PowerPac Universal power converter are provided by circuit elements L1, L2, L3, C1, C4, C5
and C6. Unit protection against short-term high voltage transients on the incoming power lines is provided by
MOV1. AC inrush current magnitudes are limited to safe levels by resistor R54 when S1 is placed in an ON
position. This resistor is bypassed by the dual contacts of relay K2, which is energized a short time after the
auxiliary power converter circuit of the PowerPac Universal becomes active. The coil of K2 is controlled by
transistor Q8 and comparator IC U8B. The output state of U8B, in turn, is determined by sampling the volt-
age of the +12V output of the auxiliary converter via resistor R50 and R51 and comparing the sample
against the +2.5V potential of reference IC U4. When this voltage sample exceeds the reference value, the
output of U8B will go to a low state, turning on Q8 and allowing the coil of K2 to be energized. Capacitor
C50, in conjunction with the sampling network resistances, provides the desired time delay for K2 activation.
This time delay value is set to be long enough to allow the capacitance filter elements of both of the two AC-
DC rectifier/filter networks to reach their full potentials before the inrush current resistor is bypassed by the
contacts of K2.

Resistor R52 provides bias current for the reference IC U4. Resistor R53 provides for a small hysteresis in
the trip points for comparator U8A, while resistors R46 and R55 are pull-ups for the outputs of comparators
U8A and U8B, respectively. Diode CR21 provides a safe discharge path for the inductive energy in the coil of
relay K2 when it is de-energized, while CR37 provides for a low-impedance discharge path for the energy in
capacitor C50 when the PowerPac Universal system is turned OFF.

Resistor R51, diode CR31 and opto-diode in OC2 provides a safe path for discharge of the energies of the
filter elements when the AC power is removed. The last two elements in this discharge path are also associ-
ated with the AC Power Good Detector circuit.

2.6.2 HV AC-DC Rectifier and Capacitor Filter Banks

2.6.2.1 Main Rectifier and Capacitor Filter Bank
The AC output of the UPS EMI filter network is rectified by the main diode bridge element BR1 to produce
a high-voltage DC potential of across capacitor bank C9, C10, C11, C12, C57, and C58. Resistors R2 and
R3 provide discharge paths for this capacitor bank when AC power is removed from the unit, as well as
equalization resistance for the bank such that the DC voltage across C9, C11 and C57 match that across
C10, C12, and C58.
When the incoming AC voltage is nominally 120CVAC, BR1 and capacitor bank are configured automati-
cally to be a “voltage-doubler” network. When the incoming AC line is nominally 240VAC, the configura-
tion of BR1 and the capacitor bank is changed to be a full-wave rectifier circuit. The configuration change
is performed by the contacts of the relay K1 in the AC Line Autorange Control subsystem, see Section
2.4.3.

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System Overview

2.6.2.2 Low-Power Rectifier and Capacitor Filter Bank

The AC output of the PowerPac Universal EMI filter network is also rectified by a lower-power diode
bridge element BR2 to produce a high-voltage DC potential across capacitor bank C24, C72, and C99.
This potential is used by the Auxiliary DC-DC (“Housekeeping”) Converter Network as a source of power,
see Section 2.4.7. Unlike the main rectifier and filter network noted in Section 2.4.2.1, the configuration of
this rectifier and filter network is NOT changed by the AC Line Autorange Control subsystem (see Section
2.4.3) and remains as a full-wave bridge and filter network regardless of the value of the incoming AC
power line voltage level.

2.6.3 AC Line Autorange Control

The PowerPac Universal is designed to be operated from either 120VAC or 240VAC as a source of input
power without requiring the user to manually reconfigure the main internal HV rectifier (BR1) and its associ-
ated capacitor bank circuitry, see Section 2.4.2. The reconfiguration is performed electronically by the cir-
cuits in the AC Line Autorange Control subsystem.

Diode D24 and capacitor C26 form a simple half-wave rectifier to generate a DC voltage across C26 that is
directly proportional to the peak magnitude of the AC voltage at the output of the PowerPac Universal EMI
Filter Network, see Section 2.4.1. A sample of this voltage magnitude is then produced by a resistive divider
network formed by R15, R16, and R17. If this voltage sample is greater than the zener voltage of VR1, then
transistor Q2 is turned on completely, reducing the gate-to-source potential of Q1 to less than one volt such
that this MOSFET is turned OFF. With Q1 off, the coil of relay K1 is de-energized. With K1 in an “OFF” state,
the connection path formed by its two set of contacts from the center connection of the main filter capacitor
bank is then removed. The bridge diode BR1 and the associated main filter capacitor bank then act as a full-
wave rectifier and filter network. The values of the resistances in the resistive sampling network have been
selected such that zener VR1 will conduct when the AC voltage from the EMI filter has a nominal RMS value
of 145V greater. Therefore, the operations discussed above will occur when the AC voltage is in the range
expected when the user AC potential is nominal 240VAC.

If the voltage sample noted above is less than the zener potential of VR1 (120VAC operation), then MOS-
FET Q1 is allowed to be turned ON via bias resistor R12 and R13 tied to filter capacitor C26. Transistor Q2
is then placed in an active state (not fully ON) by the voltage developed across resistor R11 by the source
current of Q1. In this case, Q1 and Q2 are turned ON to a point where the gate-to-source potential for Q1 is
sufficient to develop approximately 1V across resistor R11, for a drain current level of about 1/51.1 or 19.6
mA. Diode CR4 conducts in this stage with an approximate voltage drop of 0.5 volt. Capacitor C25 provides
for filtering of the gate voltage of Q1. Capacitor C23 and resistor R14 also are used for noise filtering of the
base-to-emitter junction voltage of Q2.

The drain current value of Q1 is insufficient to energize the coil of K1, and its dual set of contacts will then be
the closed positions 5-6 and 3-4. With K1 “ON”, BR1 and the main filter capacitor bank now form two
stacked half-wave rectifier-and-filter networks to produce a total DC voltage across the capacitor bank of
approximately the same value that would be observed if the unit was operating from 240VAC power.

Zener CR20 insures that the voltage across the coil of K1 will be on the order of 24VDC regardless of the
voltage value seen across capacitor C26 when the PowerPac Universal is operating from a 120V nominal
AC power source (i.e., Q1 active). The P-N junction of CR20 also serves to clamp the voltage across the coil
K1 to about 1V whenever Q1 returns to an OFF state (i.e., provides a path for dissipating the inductive
energy of the relay coil when it is de-energized).

2.6.4 Dual Main Power Converter Circuitry

The heart of the PowerPac Universal is the main DC-DC switch-mode power conversion subsystem. The
configuration of the converter subsystem used is that of two identical “flyback” converter circuits whose
inputs are connected in parallel, with their outputs connected in series. The converter circuits and connec-

2-6 100-2754C 10/08

 System Overview

tion methods are illustrated in figures 2-2 and 2-3 respectively. To prevent undesirable interactions and to
optimize power delivery performance, the two converters are operated in a time-synchronized fashion.

1 L5 4
+ +
+
C44 Vout 1
-
Vin 1 1:n 5
2 CR18
Drive 1 Q6/Q12
3
-

6 L6 9
+ +
+
C45 Vout 2
-
Vin 2 1:n 10
7 CR19
Drive 2 Q7/Q13
8
-
Dual DC-DC
n=27/40 turns ratio Flyback Converters

Figure 2-2: Converter System Circuits

In figure 2-2, the power paths of one-half of the system topology are formed by Q6, Q12, CR18 and an out-
put filter capacitor C44. The other half of the system is formed by Q7, Q13, CR19 and filter capacitor C45.
The term “flyback” has been applied to the topology used for both halves of the conversion system to depict
the “energy store and then release” operational character of those circuits.

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System Overview

Vin = Vin2 = V1
Vout = Vout1 + Vout2
1 4 +
Iout
_ 3 5
+
Vout
V1 8 9
Iout
6 10 _
V1 = HVDC Value Iout
2 7
Drive 1
Drive 1

Ts
Drive 1 ON OFF
Timing Control

Drive 2 OFF ON
Timing Control
Ts / 2 Ts / 2
Vout 1 = Vout 2 = Vout/2

Figure 2-3: Input/Output Converter System

Figure 2-3 shows the connection schemes for the two converter circuits relative to their inputs and outputs,
along with the timing used for driving each circuit to prevent interference and to optimize performance.

The mode of energy storage of the “flyback” topology in each half of the system is typically discontinuous
over any one switching period. For example, in the lower converter circuit in figure 2-2, energy is first stored
in the magnetic field of inductor L6 whenever Q7 and Q13 are ON, and subsequently used completely for
supplying one-half of the output load power when these two MOSFETS are turned OFF. The switching
period (Ts) for each converter is nominally 40 microseconds, for a switching frequency (fs) of 50 kHz. Note
that the phasing of the windings of L6 are such that diode CR19 is reverse-biased whenever Q7 and Q13
are ON, and is forward-based whenever energy is being delivered to the PowerPac Universal load via the
secondary winding of L6. During the ON times of Q7 and Q13 during a switching period, output power is
maintained by the energy stored in capacitor C45 whenever CR19 is not conducting.

Under typical operational conditions of load values, the basic power transfer characteristic of the PowerPac
Universal converter system in figure 2-3 can simply be expressed ideally in equation from as:

2
Pout = 2[Vout Iout] = 2[1 Lp Ip] (1)
2 2
with Ip = V1 ton and: ton < Ts (2)
Lp 2
Figure 2-4: Equations

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 System Overview

where Pout = PowerPac Universal output power in watts, Vout and Iout as DC output voltage and current mag-
nitudes respectively, Lp = open-circuit primary inductance of L5 or L6 (pins 1,2 to 17,18) in henries, Ip = peak
drain current value in amperes at the time Q6 and Q12 or Q7 and Q13 is turned OFF, V1 as the +HVDC volt-
age at pins 1,2 of inductor L5 or L6 relative to PWRGND in volts, ton as the total ON time of Q6 and Q12, or
Q7 and Q13 during a switching period (Ts) in seconds, and fs as the switching frequency in Hz of each one
of the two power converter circuits.

In the case of the PowerPac Universal converter system, the switching frequency of each converter is main-
tained at a constant value of 50,000 Hz. From the relationships shown earlier in equations 1 and 2, it can be
seen that the ON times of Q6 and Q12, or Q7 and Q13 can then be increased or decreased to accommo-
date changes in output power needs as well as changes in the values of the HVDC potential with variations
in the incoming AC power source for the PowerPac Universal. The adjustment of the ON times of these two
sets of MOSFETS is performed by the pulse width modulation (PWM) control system of the power system of
the PowerPac Universal.

To provide an isolated interface for obtaining the two DRIVE signal needed for the converter power stages
(see figure 2-3) from the PWM control system, a dual-secondary pulse transformer (T2) is used for this pur-
pose. Transistors Q4, Q5, Q10, and Q11 are used to provide low-impedance paths for discharging the gate-
to-source capacitive energies of the four MOSFETS in the power stages when these devices are turned
OFF by the PWM controls via the secondaries of T2. Resistors R29, R31, R77, and R79 control the base
current levels of the four turnoff transistors, while resistors R30, R32, R78, and R80 provide low impedance
paths for the gate-to-source connections of the four power MOSFETS in the power stage areas. Diodes
CR11, CR12, CR29, and CR30 provides direct paths around the turnoff circuitry for turning ON the power
MOSFETS in the power stages when the PWM control signals require either half of the PowerPac Universal
converter system to become active.

The primary winding of T2 is controlled by the two outputs of the PWM control system obtained from two
complementary non-inverting driver ICs contained in U10. Resistor R25 provides for current-limiting of the
drive signals, while capacitor C35 is used to provide DC isolation of the drive signals to prevent T2 satura-
tion should the complementary drive signal from U10 not be perfectly matched.

Two sets of transient “snubber” networks are provided across the primary windings of both inductors L5 and
L6 to provide paths for the leakage inductance and parasitic energies associated with these magnetics.
These snubbers are needed to assure that the OFF voltages seen by the four MOSFETS in the power stage
remain within their rated values while these inductive energies are eliminated during each conversion
switching period. The “leakage inductance” snubber networks are composed of CR22, R44, R68 and C51 in
the converter circuit associated with L5, while CR23, R45, R69 and C52 are the snubber elements in the
other converter circuit associated with L6. To reduce the high-frequency parasitic “ringing” potentials that
occur across the primaries of L5 or L6 at the times when output diodes CR18 or CR19 turn OFF, a second
set of primary snubber networks has been added for this purpose. Capacitor C73, diode CR25, and resistor
R67 form one of these “ring-reducing” snubber circuits, while capacitor C79, diode C26 and resistor R72
form the other circuit.

On the output side of the converter network, RF inductors L7 and L11 and capacitor C49 are high frequency
filter elements used to reduce switching noise on the DC output line of the PowerPac Universal system. A
sample of the output voltage value for the control system of the PowerPac Universal is obtained via the
resistive divider network formed by R40 and R41. Capacitor C48 is a noise filter for this divider network.

For additional filtering of high-frequency noise levels across the main output capacitor bank (C44 and C45),
a small-valued ceramic capacitor (C46 and C47) has been placed in parallel with each of them. Diodes
CR33 and CR34 have been added for voltage-reversal protection of the output load terminals of the Power-
Pac Universal.

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System Overview

A sample of the currents in the two flyback power converter stages is also needed for the control system of
the PowerPac Universal power stages. These current samples are obtained directly via a small current
transformer (T1) whose primary windings (1-turn each) are placed in series with the primary windings of L5
and L6. The secondary winding of T1 is then used to step-down the magnitude of the primary current sam-
ples by a factor of 100 (i.e., by the secondary-to-primary turns ratio of T1). The resultant bipolar current sam-
ple is then rectified via a full-wave bridge network (diodes CR13, CR14, CR15, CR16) and used to develop
a voltage across resistor R28 that will be proportional to the actual current levels in the PowerPac Universal
power stages. Capacitor C39 is a simple noise-filter element for the voltage across R28.

2.6.5 Main PWM Control Network

To provide control of the ON time of the four power switches in the power stage of the PowerPac Universal,
a fixed-frequency dual-output pulse-width-modulation (PWM) network is used. The heart of this network is
U5, a UC3825A IC, which contains all essential parts of the PWM, including the 100 kHz clock generator.
The PWM converts an analog combination of error signals from the voltage feedback network and the volt-
age analog of the currents in the power stage (R28 voltage) to time-varying drive signals for the MOSFETS
in the power stage of the PowerPac Universal. This particular PWM design employs current-mode control
measures for optimal regulation of the output voltage and current levels from the converter over the desired
ranges of loading.

Using error voltage information from the Section 2.4.6 (ERROR AMPLIFIER AND CONTROL NETWORK)
along with samples of currents in the primary side of the converter system (via T1 and R28), the PWM sec-
tion of the U5 converts this information into dual output DRIVE signals (pin 11 and 15 of U5) for the Power-
Pac Universal main converter system. U5 also contains various protective functions, including “soft-start” of
the PWM output signals current limit, over-current and leading-edge “blanking” timing control to prevent cir-
cuit noise from terminating the DRIVE signals early during a switching period. This latter protective function
is accomplished by the circuits in U5 attached to pin 4, along with an external RC network composed of
resistor R20 and capacitor C29.

The length of the “soft-start” feature of U5 is set by the value of capacitor C30 attached to pin 8. External
shutdown of the PWM functions of U5 is accomplished by the circuit formed by diode CR25, resistor R19
and MOSFER switch Q3, also tied to pin 8 of U5. A logic HIGH signal (>3V) applied to the anode of CR5 by
the PowerPac Universal central control circuits will cause all PWM functions of U5 to be immediately termi-
nated. PWM operation will continue when the logic signal at CR5 is changed to a LOW state (<1V).

Should the current samples taken from the power stages of the PowerPac Universal be excessively large,
indicating and overload condition, the voltage across R28 will increase to above 3V in peak value. This volt-
age is divided down via the resistive network formed by R26 and R27 to produce a >1V level at pin 9 of U5,
causing the internal fault logic of U5 to be activated. This action immediately terminates any output DRIVE
signals from U5 until the next switching period occurs. Capacitor C36 tied to pin 9 of U5 is a noise-filtering
element for the current limit pin.

The internal error amplifier (E/A) of U5 is not used in the overall feedback control system of the PowerPAc
Universal, other than to provide an inversion-and-DC gain function for the feedback signal area. Resistor
R23 and R24 tied to pins 1 and 3 of U5 set the effective DC gain value of the E/A at nominally two. Capacitor
C37 is a high-frequency noise filter element for the E/A.

Values for resistor R19 tied to pin 5 and capacitor C27 tied to pin 6 of the U5 have been selected to set the
PWM oscillator/clock frequency of U5 at a constant value of nominally 100kHz. At the start of a switching
period, one of the two output pins of U5 produces 10V to start a drive pulse for the main converter stage,
while the other output pin remains at ground potential during this interval. When the internal clock starts
another switching period following the first, the steering logic of U5 causes the output that was at ground
potential to generate a 10V drive signal and keeps the other output that was originally producing a drive sig-
nal now at ground potential. Therefore, the output of U5 alternate in producing drive commands, assuring

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 System Overview

that the power stages of the PowerPac Universal overlap in operations at a frequency of 1/2 that of the PWM
clock, or 50kHz.

When the level of the sample voltage across resistor R21 (plus an internal 1,25V bias in U5, pin 7 area)
matches the error voltage level at pin 3 of U5, any DRIVE outputs from U5 are terminated until the next
switching period of the PWM. The voltage across resistor R21 is a combination of the dynamic voltage
across resistors R28/R89 produced by the current transformer T1 and a small part of a dynamic “ramp” volt-
age that appears across capacitor C27 in the clock oscillator area. The capacitor voltage is buffered by tran-
sistor Q9 and reduced in amplitude by resistor R76 and the effective resistance seen at pin 7 of U5. This
“ramp” provides for adequate signal level to be present at pin 7 when the PowerPac Universal load is small
in value - this is needed to insure that U5 will produce the necessary PWM signals for the power stage under
“light-load” conditions when the current amplitudes in the windings of T1 will be small.

U5 also contains a voltage regulator circuit which provides a fixed 5V potential for its internal circuits. The
power for this regulator comes form the +12V output of the auxiliary power converter network. Capacitor C34
and C82 are filter components for the +12V line at U5’s location, while capacitor C28 is a de-coupling ele-
ment for the 5V output of U5 (labeled as VR at pin 16).

To prevent transient excursions of the DRIVE output waveforms form the buffer IC U10 during turn-on and
turn-off intervals from damaging this part, two diode voltage “clamp” networks have been provided on the
two output pins of U10. Each clamp circuit consists of two Schottky diodes. These diode types of the power
variety (CR6 and CR8, and, CR7 and CR9) are used here to insure the clamp voltage drops will be small,
with two diodes tied to the +12V line (CR6 and CR7) and the others (CR8 and CR9) tied to the output ground
potential of the PowerPac Universal (GND).

2.6.6 Error Amplifier and Control Network

The sample of the output voltage provided by R40 and R41 in the main DC-DC converter subsystem is used
by the PowerPac Universal controls to monitor the potential level of the PowerPac Universal output. This
sample, along with a sample of the output current magnitude, is compared with a precision reference voltage
set by the PowerPac Universal central controls and then used to produce an error signal for the PWM con-
trol network. This error signal then causes the system to make adjustment in the ON time of the power
switches in the main converter areas so that the output voltage and/or output current level remains constant
with changes in AC power and/or load resistance.

A buffer amplifier and filter network formed by U9, R73, R74, and C33 are used to apply the output current
sample to the reference control area of the PowerPac Universal. Resistor R43 is used to set the DC voltage
gain of U9 to boost the voltage across R42 produced by the output current to a proper level for control pur-
poses.

For the output voltage sample, U32A, R70, R71, and C81 form a buffer network for this sample signal. U12A
provides the proper signals to the PowerPac Universal output control network using the buffered samples of
output voltage and current. IC U13A provides a proper reference voltage for the power stages of the Power-
Pac Universal, based on the user settings for output voltage and current levels. U26 provides a highly regu-
lated 2.5V bias voltage for the operations of U13A and U14A, using the +12 output of the auxiliary power
converter of the PowerPac Universal. The output of the U13A is buffered, inverted and amplified by U25A
and U25B in conjunction with resistor R47, R48, and R49.

To provide short-term over-voltage protection for the buffer areas related to the output current or voltage
samples, detection circuits have been provided for these purposes. These circuits are formed by U34A,
U34B, U28E, U28F, and resistors R85, R86, R87, R88 in the PowerPac Universal assembly.

The set-point voltage produced by U25B varies from 0 to close to 0.5 volts in magnitude, depending on the
setting for desired value of output voltage or current. This voltage is then compared against the sampled

100-2754C 10/08 2-11

System Overview

value of the actual output potential of the PowerPac Universal, using a simple inverting amplifier system.
This system is formed by U6A, R35, R38, R39, R36, and capacitors C40 and C41.

Resistors R36 and R39 provide a slight negative voltage bias on the non-inverting terminal of U6A such that
the PWM subsystem will be turned OFF reliably whenever the control system is in a “standby” mode (i.e.,
the output voltage and/or current level is set to zero value). This bias also assures that the PWM subsystem
will not cause the unit to produce full power when the shutdown command is removed. The negative bias
source is the -0.7V potential generated by the forward voltage drop of diode CR17. Resistor R37 provides a
path from the -12V (generated by the auxiliary power converter - see Section 2.4.7) to provide the bias cur-
rent for CR17. Capacitor C42 is a high frequency noise reduction element for pin 3 of U6A. Capacitor C90 is
a filter element for the -0.7 potential of CR15. To provide for input offset compensation, the value of R39 has
been selected to be the same as R38. Resistor R35, along with capacitors C40 and C41, are the feedback
elements of the U6A error amplifier. Their values, as well those selected for R38 and R39, have been care-
fully chosen to provide adequate margin in overall feedback control stability for the PowerPac Universal
power conversion system under all specified input line and output load conditions.

To provide a proper inverting interface between the output of the error amplifier U6A and input of the ampli-
fier in the PWM IC U5, a buffer network formed by U6B, diode CR10, resistors R33, R34, R58, and capacitor
C96 has been added. U6B uses the U5 reference voltage as the potential for its non-inverting input (pin 5)
as does the non-inverting input pin 2 of U5. This provides a level translation through U6B so that its output
pin 7 is biased at approximately +3V. Diode Cr10 insures that the input voltage to the error amplifier within
U5 can never be negative in magnitude, which could occur during a startup sequence of the PowerPac Uni-
versal converter system. Capacitor C96 is a high-frequency bypass element for the feedback resistor around
U6B.

2.6.7 Auxiliary DC-DC Converter Network

A second switch-mode power converter network is included in the PowerPac Universal power system to pro-
vide voltages for the various analog and digital control circuits, as well as potentials for the PWM control and
drive circuits. This network is called the “housekeeping” power converter for this reason, as it operates inde-
pendently of the main DC-DC power converter stage.

This converter subsystem produces three DC voltages (+12V, -12V, and +5V) for the PowerPac Universal.
The +12V is also used for powering the PowerPac Universal cooling fan assembly whenever the auxiliary
converter is on.

The power source for this special converter is generated form the user’s AC line, using the AC potential from
the output of the EMI filter network. This provides a rapid turnoff of the PowerPac Universal display and fan
when the unit AC power is removed, even though the energies stored in the main capacitor bank (C11, C12,
C57, and C58) have not been fully discharged. A small diode bridge element BR2 is used to rectify the AC
potential and capacitors C24 and C27 are used to filter the rectified AC to produce a high-voltage potential
for operating the housekeeping DC-DC converter.

Like the main DC-DC power converter circuits of the PowerPac Universal, the auxiliary power converter cir-
cuit is a discontinuous “flyback” design, with L4 serving as the magnetic storage element. However, unlike
the main DC-DC power conversion system, it is a fixed-frequency design that operates primarily in a current-
limit mode whenever it is active (often called a “burst-mode” converter). The heart of the converter is its con-
trol IV U1, which contains all of the central clock and control elements for a switching regulator of this variety,
including a high-voltage MOSFET switch for the power stage. It also has an internal thermal shutdown circuit
that will disable the operations of the IC in abnormal temperature conditions. It also includes auto-start, line
under-voltage sense and frequency of the housekeeping converter is 130 kHz.

Resistor R5 and R6 provide a bias for U1 such that the rectified AC line voltage value across C24, C72 and
C99 must be at least 100 VDC before U1 is allowed to function to permit the housekeeping converter to

2-12 100-2754C 10/08

 System Overview

become operational. Capacitor C15 is a high-frequency filter capacitor for the internal 5.8V reference voltage
produced by U1 at pin 3 of this IC.

ON-time duty cycle control of the power switch in U1 is accomplished by voltage control of the potential at
the EN/UV (pin 1) of this IC. This function is provided by opto-coupler OC1 which provides isolation of the
power ground of the auxiliary converter (AUXGND) from the output ground (GND) of the PowerPac Univer-
sal. The level of conduction of the transistor in OC1 is controlled by a small feedback and control network on
the output ground side of the converter. This network is composed of resistors R8, R9, R10, capacitor C20,
and a voltage reference IC U2. Drive power for opto-diode in OC1 is provided via resistor R7 tied to the
+12V output voltage line of the auxiliary converter.

U2 contains both a 2.5V reference voltage element and an operational amplifier. A sample of the +12V out-
put is provided via the resistive divider network formed by R8 and R10. This sample is then compared inter-
nally in U2 to its reference potential, with any difference then amplified to produce an error voltage at its
output pin (pin 1). Since the opto-diode in OC1 is tied to this product pin, changes in the error voltage from
U2 will cause this diode to conduct more or less and in a direction so as to adjust the ON time of U1 to main-
tain the +12V output constant with changes in loading, as well as the DC input voltage at pin 1 of inductor L4.

Diode CR2 and capacitor C16 and C18 are the output elements of the converter for the +12V potential. A
small low-pass filter network (inductor L9 and capacitor C82 and C34) is used and helps to reduce high-fre-
quency voltage ripple caused by the operations of the auxiliary power converter on the 12V output point.
Capacitor C20 serves as the single feedback compensation element for the +12V regulator network for sta-
bility of control. Capacitor C8 provides an AC connection for the power and output grounds for lowering high
frequency EMI emission levels.

A separate winding on inductor L4 is used to generate the raw potential for powering a linear voltage regula-
tor IC (U3) used to generate the +5V line. Diode CR28, along with capacitor C67 and C78, form the rectifier/
filter network for developing the raw input potential for U3. The nominal voltage value seen across capacitor
C7 and C78 is on the order of +6VDC so that the power dissipated in linear regulator U3 is kept to a mini-
mum amount.

Another secondary winding on L4 is used to generate the -12V potential for the PowerPac Universal elec-
tronic display and control. Diode CR3 and capacitor C17 and C19 are the rectification and filter elements
associated with the -12V output. Regulation of this potential is indirect in nature in that this potential will
“track” that of the regulated +12V output since all secondary windings on L4 are magnetically coupled.
Inductor L9 and capacitor C84, C85 and C91 are high-frequency filter elements for the -12V output.

Note: The two 12V output voltages of the PowerPac Universal auxiliary supply can vary significantly in value
without affecting the accuracy or operations of the unit. Critical reference potentials used in the controls of the
PowerPac Universal are derived using precision regulator elements that are powered from these voltages.

Two snubber circuits are provided on the primary side of L4 for safe retrieval of the leakage energies in this
inductor when U1 is turned OFF. One of these networks is a voltage “clamp” design (diode CR1, capacitor
C14 and resistor R4) to keep the maximum drain voltage level (pin 7 on U1) within rating value. The second
network is a simple RCD noise-suppression snubber (resistor R60, capacitor C59, and diode CR38) also
placed directly across the primary winding of L4.

2.6.8 Power Good Detector

To provide an electrical indication that the incoming AC power is present, a simple voltage detector circuit
powered from the +5V output is used. The Power Good Detector (PGD) signal generated by this detector is
used by the PowerPac Universal logic to provide an early indication to the PowerPac Universal electronics

100-2754C 10/08 2-13

System Overview

that the AC power for the PowerPac Universal power conversion system has fallen out of tolerance or has
been removed.

The AC level of the output of the EMI filter network of the PowerPac Universal (see Section 2.4.1) is used for
detection of a “brown-out” or power loss situation. When the AC voltage is positive (PHASE-A) with respect
to its return line (PHASE_B), the diode in opto-coupler OC2 is permitted to conduct, turning ON the opto-
transistor in OC2. With this transistor ON, diodes CR32 and CR36 do not have sufficient bias to remain in a
conducting state, causing transistor Q10 in the Power Good Detector circuit to be turned OFF. This action
produces a positive PGD signal for the PowerPac Universal system.

When PHASE_A becomes negative in potential with respect to PHASE_B, diode CR31 is permitted to con-
duct, causing the diode in OC2 to be reverse-biased. This action causes the opto-transistor in OC2 to be
turned OFF. With this transistor in an OFF state, voltage across capacitor C97 begins to build up at a rate
determined by the resistive-capacitive time constant of this capacitor in conjunction with resistor R75. If the
potential of C97 reaches about 1.5V, diodes CR32 and CR36 become forward-biased as does the base-
emitter junction of transistor Q16, allowing this transistor to turn ON. This action then produces a low indica-
tion level of the PGD signal, signaling a probable short-term loss of AC power to the unit.

However, if capacitor C97 is discharged by the opto-transistor in OC2 being turned ON before the 1.5V
detection threshold is reached, then Q16 will remain in an OFF state, and the PGD signal will continue to be
positive in value. The RC time constant of the R75-C97 network is such that approximately one complete
cycle of the incoming 50 or 60Hz AC power to the PowerPac Universal must be lost before the detector cir-
cuit will give a low PGD signal to the PowerPac Universal system. This provides adequate time for the Pow-
erPac Universal controls to be set in a safe state before the main power converter system starts to lose
regulation control of the output voltage should the AC power be lost completely.

Resistor R58 is a pull-up resistor for the PGD output, allowing the PGD output to be close to 5V when tran-
sistor Q16 is in OFF state. Resistor R81 serves to provide a low-impedance path across the base-emitter
junction of Q16 to prevent turn-on of this transistor from collector-base leakage current and provides some
noise immunity for the base-emitter junction of Q16 whenever diodes CR32 and CR36 are not conducting.

2.7 Temperature Sensor

The temperature sensor shuts down the converter when the temperature exceeds about 58 °F near the air entrance point in
the front of the unit. The processor receives this signal, sounds the audible alarm, and puts a message on the LCD inform-
ing the operator of error code 17, overtemperature. The unit then will wait until the temperature inside the unit decreases.
After that occurs, the operator can continue the current run. Operator intervention is necessary for operation to continue.

2.8 Operation with a Personal Computer and PDA

The PowerPac Universal is capable of transmitting methods to and from a Personal Digital Assistant (PDA), or
transmitting run data to a personal computer (PC) or PDA through the infrared (IR) port located on the front of
the power supply.

2.8.1 Operation with a Personal Computer

Communication between a PowerPac Universal and a PC requires that the PowerPac Data Remote soft-
ware (164-5067 includes PDA software also) be installed on a compatible PC. The PowerPac data transfer
software for PC is compatible with computer running the Windows 2000™ or Windows XP™ operating sys-
tem and that includes an IR port. The PowerPac Data Transfer Software is used to transmit run data from
the PowerPac Universal, or PDA, to a PC.

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 System Overview

2.8.2 Operation with a PDA

Communication between a PowerPac Universal and a PDA requires that the PowerPac Data Remote soft-
ware (164-5067, includes PDA software also) be installed on a compatible PDA. The PowerPac Remote
software for PDA is compatible with any PDA that runs Palms OS version 4.0 or above, and 16 MB of mem-
ory. With the PowerPac Remote software the PDA can perform the following functions:

• Transmit methods to and from the PowerPac Universal

• Transmit data from the PowerPac Universal
• Transmit data to a PC
• Store up to 20 methods
• Store up to 20 data files
• Provide unique data file identification

2.9 PowerPac™ Universal Front Panel

Alphanumeric
Start/Pause Key Keypad
Insulated Jacks
Stop/Home Key

Function Keys Cursor Keys

Edit Key IR Port
Setup Key

Figure 2-5: Front Panel

Feature Description
Start/Pause Key Starts and Pauses the run. When paused, the run parameters for the current or
subsequent step(s) may be edited. The modified method may be stored to per-
manent memory by pressing SAVE at the of the run.
Stop/Home Key Terminates the run in progress and displays the final run parameter, or if no
run is active, changes the display to the Home screen.

Note: If a method has been edited during a run, SAVE must be

pressed at the end of the run to save the changes.

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System Overview

Feature Description
SETUP Key Used to set the PowerPac Universal default parameters. Parameters includes:
power failure detection, rapid resistance change detection, no load detection
as well as clock, contrast and key chirp setting.
EDIT Key Toggles soft key assignments between those used to set the run mode (con-
stant voltage, constant current or constant power), run limits (voltage, current
or power) and time mode (hours, volthours or untimed).
UP and DOWN Keys Scrolls through the methods in the methods list and scrolls through the steps
and name of an open method. The “*” points to the selected method or step.
CE Key Clears alphanumeric entry to previous value.
Alphanumeric Keypad Enter parameter values and method names.
IR Port The PowerPac Universal is capable of transmitting methods to and from a
PDA (Personal Digital Assistant), or transmitting run data to a personal com-
puter (PC) or PDA through the IR port located on the front of the power sup-
ply.

Note: Communication between a PowerPac Universal and a PC

requires that the PowerPac Data Transfer software (catalog number
164-5067, includes PDA software also) be installed on a compatible
PC.

2.10 PowerPac™ Universal Rear Panel

Power Switch

AC Inlet
Fuses
Fan

Figure 2-6: Rear Panel

2.11 Safety
The PowerPac™ PowerPac Universal uses high output voltages that are electrically isolated from earth ground
to minimize the risk of electrical shock to the user. The following guidelines should be observed when using a
PowerPac Universal power supply.

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 System Overview

The PowerPac™ PowerPac Universal can be operated at temperatures between 0 to 40 °C with relativity
humidity between 0 to 95% non- condensing. Operating the power supply outside these conditions is not rec-
ommended by Bio-Rad and will void the warranty.
1. To ensure adequate cooling of the power supply, be sure that there is at least 6 cm clearance around the power supply.
Do not block the fan vents at the rear of the unit.
2. Always connect the power supply to a 3-prong, grounded AC outlet, using the 3-prong AC power cord provided with
the power supply.
3. Bio-Rad electrophoresis cells have molded two-prong plugs that are inserted into the power supply’s high voltage
output jacks. These plugs have been EN61010 certified for safety compliance for use with PowerPac power supplies.
Use of other plugs or banana jacks is done at the user’s own risk and is not recommended by Bio-Rad. When inserting
and removing the molded two-prong plug, always grasp the plug by the molded support at the rear of the plug. Do not
grasp the individual prong ends.
4. Do not operate the power supply in extreme humidity (>95%) or where condensation can short the internal electrical
circuit of the power supply.
5. When taking the power supply into a cold room, the unit can be operated immediately. However, when removing the
power supply from the cold room, let the unit equilibrate to room temperature for a minimum of two hours before
using it.
6. Never connect a high power outlet lead to earth ground. This defeats the floating electrical isolation of the power sup-
ply and exposes the user to potentially lethal high voltages.

2.12 Specifications

Performance Power Pac™ Universal Power Supply

Input Power (nominal) 100-120/220-240 VAC, 50/60 Hz, Autoswitching.
Type of Output Constant Voltage, Current, or Power with automatic crossover.
Output Voltage 10-500V @ 2.5A and 500W, 1 V increments.
(Note: Minimum Power is 1W)
Output Current 10-2500 mA, 1 mA increments from 10-2,500 mA.
(Note: Minimum Power is 1 W)
Power Range 1-500W, fully adjustable 1 W increments
Timer mode 1 minute to 99 hours, settable in 1 minute increments.
Time Option Optional, user programmable low voltage hold step.
Pause/resume function Yes
Voltage Accuracy ± 2% above 50V, ± 1volt less than or equal to 50V.
Current Accuracy ± 2% above 250mA, ± 5mA less than or equal to 250mA.
Line Regulation ±1% at 500V.
Load Regulation ± 1% with 50% load change.
Ripple 2V or 2% peak-to-peak, whichever is greater.
Output Drift ± 0.5% per hr after 30 min warm-up.
No Load Less than or equal to 2mA
Current Leakage Less than or equal to 500µA
Number output jacks Four pair of recessed banana jacks in parallel.

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System Overview

Readout Stability Voltage: ±1%, Current: ± 1%.

Display Functions Volts, Amps, Watts, Time remaining if timer set, and time elapsed if
timer not set.
Display 128 x 64 Monochrome Backlit LCD.
Operating Conditions 0 - 4°C; 0-95% Humidity in the absence of condensation.
Dimensions 27.5 cm X 9.8 cm X 34.5 cm.
Weight 2.5 kg.
Safety Features • Outputs are isolated from ground
• Shut-off on sudden change in load, with provision for disabling
• Will not run without load connected, 2mA minimum
• Short Circuit detection, less than 50 Ohms
• Hardware over-voltage, over-current shutdown
• Microcontroller watchdog, shutdown if microcontroller fails
Input Protection Fuse on Hot and Neutral.

2-18 100-2754C 10/08

 Installation

Section 3
Installation

3.1 Introduction
This section of the manual guides you through the installation and the setup of the PowerPac™ Universal
power supply. Successful completion of the installation in the Installation section represents a preliminary sys-
tem checkout of the instruments.

3.2 Unpacking the PowerPac Universal

When receiving the power supply, carefully inspect the container for any damage which may have occurred in
shipping. Severe damage to the container may indicate damage to the power supply itself. If you suspect dam-
age to the unit, immediately file a claim with the carrier in accordance with their instructions before contacting
Bio-Rad Laboratories.

The PowerPac Universal power supply is shipped in a protective AirBox™. Follow the directions printed on the
AirBox to unpack the PowerPac Universal™ power supply.

Remove the plastic film from the translucent green top case. The plastic film may leave a residue. If so, clean
with a soft, damp cloth. Also remove the die-cut plastic film covering the display window.

Make sure that the customer received everything. The following is a list of the items that may be included in a
typical PowerPac Universal power supply shipment.
• PowerPac Universal™ power supply
• Power Cord
• Instruction Manual
• Warranty card
• Declaration of Conformity

If any part is missing or damaged, contact Bio-Rad Laboratories immediately.

3.3 Setting Up the PowerPac Universal

1. Attach the power cord to the three-pronged receptacle on the back of the PowerPac Universal. Plug the unit into a
electrical outlet.
2. Turn on the PowerPac Universal by turning on the power switch located on the right side of the power supply.
3. Verify that the fan runs and the display illuminates. The screen briefly displays the firmware version and the instru-
ment serial number, then the Home screen is displayed. See figures 3-1 and 3-2.

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Installation

FW Version: X.XX SELECT MODE

Serial No. XXXXXX

MANUAL METHODS

Figure 3-1: Firmware Screen Figure 3-2: “Home” Screen

4. Turn off the power supply.

3.4 Connecting the Universal to the Electrophoresis Cell

The Mini-Sub Cell GT can be used to check the performance of the PowerPac Universal.

Note: Make sure to turn off the PowerPac™ Universal before connecting or disconnecting the power cord or
any cables. To ensure adequate cooling of the power supply, be sure that there is at least six cm clearance
around the power supply. Do not block the fan vents at the rear of the unit.

PowerPac Universal

Mini-Sub Cell GT

Figure 3-3: PowerPac Universal to Electrophoresis Cell Setup

Note: The power cable male ends must be fully inserted and seated perpendicular to the curve of the case.
Recheck for proper contact seating before proceeding.

3.4.1 Connecting Power Supply/Cell at Constant Voltage

1. Remove the Electrophoresis Cell cover.
2. The buffer tank of the electrophoresis cell can be filled with a buffer such as 250ml 1X TBE.

3-2 100-2754C 10/08

 Installation

Note: 250 ml 1X TBE buffer can be made from a 10X stock of Bio-Rad premix buffer solution (161-0741). To
obtain 250 ml 1X TBE buffer, mix 25 ml 161-0741 stock solution with 225 ml Di water to produce a general
buffer solution. Make sure that the 10X TBE and the Di Water are properly mixed, otherwise the results will be
out of specification.

3. Insert the power leads between the power supply, and the electrophoresis cell. See figure 3-3.

Note: The power cable male ends must be fully inserted and seated perpendicular to the curve of the case.
Recheck for proper contact seating before proceeding.

4. Attach the power cord to the back of the power supply.

5. Plug the unit into an electrical outlet and turn on the PowerPac Universal.
6. Verify that the fan runs and the display illuminates. The screen briefly displays the firmware version and the instru-
ment serial number, then the Home screen is displayed. See figures 3-1 and 3-2.
7. Press the Setup key and make sure that the Power Failure Detection (PFd) is on, then press the Stop/Home key.
8. Using the Function keys select Manual.
9. Using the Alphanumeric Keypad enter 75 to set the Constant voltage to 75 Volts, then press the Edit key two
times.
10. Using the Function keys select HRS.
11. Using the Alphanumeric Keypad enter 3 to set the running time to 3 min, then press the Edit key once.
12. Press the Start key to run the unit.
13. Check that the power supply current reading is about 37 to 38 mA.

Note: If the instrument fails to meet the specified voltage from Section 3.4.1, check and troubleshoot the
buffer solution, distilled water, electrophoresis cell, cell connections, and power cables, then repeat the test in
Section 3.4.1.

3.4.2 Connecting Power Supply/Cell at Constant Current

1. Remove the electrophoresis cell lid.
2. Fill the buffer tank of the electrophoresis cell with a buffer such as 250ml 1X TBE.

Note: 250 ml 1X TBE buffer can be made from a 10X stock of Bio-Rad premix buffer solution (161-0741). To
obtain 250 ml 1X TBE buffer, mix 25 ml 161-0741 stock solution with 225 ml Di water to produce a general
buffer solution. Make sure that the 10X TBE and the Di Water are properly mixed, otherwise the results are
going to be out of specification.

3. Insert the power leads between the power supply, and the electrophoresis cell. See figure 3-3

Note: The power cable male ends must be fully inserted and seated perpendicular to the curve of the case.
Recheck for proper contact seating before proceeding.

4. Attach the power cord to the back of the power supply.

100-2754C 10/08 3-3

Installation

5. Plug the unit into an electrical outlet and turn on the PowerPac Universal.
6. Verify that the fan runs and the display illuminates. The screen briefly displays the firmware version and the instru-
ment serial number, then the Home screen is displayed. See figures 3-1 and 3-2.
7. Press the Setup key and make sure that the Power Failure Detection (PFd) is on, then press the Stop/Home key.
8. Using the Function keys select Manual.
9. Using the Function keys select CONSTA.
10. Using the Alphanumeric Keypad enter 38 to set the Constant Current to 38 mA, then press the Edit key two
times.
11. Using the Function keys select HRS.
12. Using the Alphanumeric Keypad enter 3 to set the running time to 3 min, then press the Edit key once.
13. Press the Start key to run the unit.
14. Check that the power supply reading is about 75 to 76 volts.

Note: If the instrument fails to meet the specified voltage from Section 3.4.2, check and troubleshoot the
buffer solution, distilled water, electrophoresis cell, cell connections, and power cables, then repeat the test in
Section 3.4.2.

3-4 100-2754C 10/08

 System Checkout

Section 4
System Checkout

4.1 Introduction
This section provides instruction for testing the PowerPac™ Universal power supply. The purpose is to verify
performance., functional integrity and to detect faulty operation of the PowerPac™ Universal power supply.
The system checkout procedure should be performed following installation or any repair or maintenance of the
PowerPac™ Universal power supply. The System Checkout procedure assumes that the PowerPac™ Univer-
sal power supply has been properly installed. Successful completion of the tests in the System Checkout sec-
tion represents proper instrument performance.

4.2 Tools and Materials

• IQ/OQ Test Box (10011694)
• 2 Each Fluke True RMS Multimeter Model 189 or equivalent (0.1% DCV and 0.15% DC mA accuracy)
• Banana Plug Adaptor (920-7369)
• High Voltage Test Cable Set (800-0838)

Caution: Hazardous high voltages exist in the PowerPac™ Universal power supply. All safety precautions
must be observed while working with hazardous voltages and servicing the PowerPac Universal.

Alphanumeric
Start/Pause Key Keypad
Insulated Jacks
Stop/Home Key

Function Keys Cursor Keys

Edit Key IR Port
Setup Key

Figure 4-1: Front Panel

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System Checkout

4.3 Power on Test

This section checks the power on condition and firmware.
1. Turn on the power supply and verify the display turns on.
2. Verify for fan movement by placing a tissue at the rear panel and checking the tissue is pushed away from the fan
vent.
3. Verify that no error messages are displayed on the screen. The screen briefly displays the firmware version and the
instrument serial number, then the Home screen is displayed. See figures 4-2 and 4-3.

SELECT MODE
FW Version: x.xx

Serial No. xxxxxx

MANUAL METHODS

Figure 4-2: Firmware Screen Figure 4-3: “Home” Screen

4.4 Rapid Resistance Change Detection/No Load Detection Test

The Rapid Resistance Change/No Load detection (RRCd-NLd) is used to determine the instrument response
due to a large change in resistance.

4.4.1 Rapid Resistance Change Detection with RRCd On

When the RRCd is turned On, and the power supply detects a load change greater than 20% or 15 mA, or
the absence of a load (current is less than 2 mA), it will cause an alarm to sound and the run to pause.

1. Make sure the IQ/OQ Test Box and the power supply are installed as indicated in figure 4-4.
2. Turn on the power supply.

PowerPac Universal IQ/OQ Test Box

500
Ohms
(+) (-)

(-) (+)

Figure 4-4: Power Failure Detection Setup with RRCD-NLDd On

4-2 100-2754C 10/08

 System Checkout

3. Wait until the Home screen is displayed.

4. Press the Setup key, then press the Function key and make sure that the RRCd-NLDd function is ON.
5. Press the Stop/Home key to go back to the Home screen.
6. On the PowerPac Universal, use the Function Keys and select Manual
7. Using the Alphanumeric Keypad enter 250 to set the Constant Voltage to 250.
8. Press the Start key to run the unit.
9. Wait about 3 seconds after the voltage reaches 250V and then remove one of the cables. The display reads an
ERROR STOP: CODE 01 and an alarm will sound in approximately 4 seconds to indicate a no load error. See
figure 4-5.
10. Select CANCEL and then press the Stop/Home key, or cycle the power to reset the error message.

ERROR STOP: CODE 01

NOLOAD DETECTED
CORRECT AND CONTINUE
RUN PAUSED.
CONTINUE CANCEL
Figure 4-5: CODE 01

4.4.2 Rapid Resistance Change Detection with RRCd Off

When the RRCd is turned Off, detection of sudden load changes or the absence of a load is disabled. When
running in this mode a symbol (See figure 4-6) is displayed on the Run screen as a reminder that this safety
feature has been turned off.

Figure 4-6: With RRCd Off

1. Make sure the IQ/OQ Test Box and the power supply are installed as indicated in figure 4-4.
2. Turn on the power supply.
3. Wait until the Home screen is displayed.
4. Press the Setup key, then press the Function key and make sure that the RRCd-NLDd function is OFF.
5. Press the Stop/Home key to go back to the Home screen
6. Using the Function keys select Manual.
7. Using the Alphanumeric Keypad enter 250 to set the Constant Voltage to 250.
8. Press the Start key to run the unit.

100-2754C 10/08 4-3

System Checkout

9. Wait about 3 seconds after the voltage reaches 250V and then remove one of the cables. The display will not read
any ERROR CODE and no alarm will sound.
10. Press the Stop/Home key and then select Exit, or cycle the power.

4.5 Overload Short Circuit Test

This section checks short circuit detection.
1. Make sure the power supply is off.
2. Insert the power leads into one of the output terminals.
3. Make sure that the power leads are shorted, as indicated in figure 4-7.

(-) (+)
Shorting the Output

Figure 4-7: Short Circuit Test Setup

4. Turn on the power supply.

5. Wait until the Home screen is displayed.
6. Using the Function keys select Manual.
7. Using the Alphanumeric Keypad enter 250 to set the Constant Voltage to 250.
8. Press the Start key to run the unit.
9. The display reads an ERROR STOP: CODE 02 and an alarm will sound in approximately 1 second to indicate an
over current error. See figure 4-8.
10. Select CANCEL and then press the Stop/Home key, or cycle the power to reset the error message.

ERROR STOP: CODE 02

OVER CURRENT
CORRECT AND CONTINUE
RUN PAUSED.
CONTINUE CANCEL
Figure 4-8: CODE 02

4-4 100-2754C 10/08

 System Checkout

4.6 Power Failure Detection Test

The Power Failure detection (PFd) mode is used to determine the PowerPac Universal response to power fail-
ures.

PowerPac Universal IQ/OQ Test Box

500
Ohms
(+) (-)

(-) (+)

Figure 4-9: Power Failure Detection Setup

4.6.1 Power Failure Detection with PFd On

If the PFd is ON, and power failure occurs, then the run will resume when the power is restored.

Warning: Turning the power supply off to stop a run in progress is regarded as a power failure and the inter-
rupted run (when PFd is on) will resume the next time the power supply is turned on.

1. Set the PowerPac Universal and the IQ/OQ Test Box as indicated in figure 4-9.
2. Turn on the power supply.
3. Wait until the Home screen is displayed.
4. Press the Setup key, then press the Function key and make sure that the PFd function is ON.
5. Press the Stop/Home key.
6. Using the Function key select Manual.
7. Using the Alphanumeric Keypad enter 250 to set the Constant Voltage to 250.
8. Press the Start key to run the unit.
9. Wait approximately 3 seconds after the voltage reaches 250V and then turn off the power supply. Wait approxi-
mately for 5 second.
10. Turn on the power supply and verify that the unit runs automatically from its previous setting and displays 250 V.
11. Press the Stop/Home key to stop the run, then press Exit and Stop/Home to go back to Home screen.

100-2754C 10/08 4-5

System Checkout

4.6.2 Power Failure Detection with PFd Off

If the PFd is Off, and power failure occurs, the display reads an ERROR STOP: CODE 07. and the run will not
resume.
1. Set the PowerPac Universal and the IQ/OQ Test Box as indicated in figure 4-9.
2. Turn on the power supply.
3. Wait until the Home screen is displayed.
4. Press the Setup key, then press the Function key and make sure that the PFd function is OFF.
5. Press the Stop/Home key.
6. Using the Function key select Manual.
7. Using the Alphanumeric Keypad enter 250 to set the Constant Voltage to 250.
8. Press the Start key to run the unit.
9. Wait approximately 3 seconds after the voltage reaches 250V, and then turn off the power supply. Wait approxi-
mately for 5 seconds, and then turn on the power supply again. The display reads an ERROR STOP: CODE 07
and an alarm will sound to indicate a power failure error. See figure 4-10.
10. Press the Reset key to reset the power supply.

ERROR STOP: CODE 07

RUN POWER FAILURE
RUN TERMINATED.
RESET WHEN READY.
RESET
Figure 4-10: CODE 07

4.7 Constant Voltage, Current and Power Test

4.7.1 Constant Voltage, Current, and Power Test at 80 Ohms.

This section checks the Constant Voltage, Current, and Power at 80 Ohms.
1. Make sure power supply is off.
2. Setup the power supply, IQ/OQ Test Box, voltmeter and current meter as indicated in figure 4-11.

4-6 100-2754C 10/08

 System Checkout

Voltmeter Current Meter

VDC mA DC
PowerPac Universal
Power Supply IQ/OQ Test Box
(+) (-)(+)
500 80
ohms ohms

(-) (+) (-) (+) (+) (-)

(-) (+)

Figure 4-11: Meter Setup for 80 Ohms

3. Turn on the power supply.

4. Wait until the Home screen is displayed. See figure 4-3.
5. Using the Function key select Methods...New...Edit, then create the following Method. See table 4-1.

Note: Press Edit to accept the values and press the Down key to create an empty step. This method contains
nine steps.

Table 4-1: 80 Ohms Method

Step Constant Limit V Limit A Limit W Time
S1 195 V 2500 mA 500 W 00:01h
S2 200 mA 200 V 500 W 00:01h
S3 20 W 200 V 2500 mA 00:01h
S4 1800 mA 200 V 500 W 00:01h
S5 20 V 2500 mA 500 W 00:01h
S6 200 V 500 mA 500 W 00:01h
S7 2500 mA 500 V 100 W 00:01h
S8 500 W 80 V 2500 mA 00:01h
S9 250 W 200 V 2500 mA 00:01h

Note: Steps S6, S7, and S8 are crossover tests. The unit will be limited by another parameter before it
reaches the setpoint on the controlled parameter.

100-2754C 10/08 4-7

System Checkout

6. Press Save to save the Method.

7. Press the Start key to run the method.
8. Verify the power supply and the meters values are within the ranges as indicated in the Voltage, Current, and
Power Specification Table. See Table 4-2.
9. If values are not within specification, then the PowerPac Universal needs to be calibrated. See Section 7.3.

Table 4-2:Voltage, Current, and Power Specification Table

Step At 80 Ohms Limited by Voltage Range Current Range Wattage Range
S1 195 V 196 - 204 V
S2 200 mA 195 - 205 mA
S3 20 W 19.6 - 20.4
S4 1800 mA 1764 - 1836 mA
S5 20 V 19 - 21 V
S6 500 mA 490 - 510 mA
S7 100 W 98- 102 W
S8 80 V 77.5 - 82.5 V
S9 250 W 245 - 255 W

Note: The Power is obtained by multiplying the Current times the Voltage value read by the meters.

4.7.2 Constant Voltage, Current, and Power Test at 500 Ohms

This section checks the Constant Voltage, Current and Power at 500 Ohms.
1. Make sure the power supply is off.
2. Setup the power supply, IQ/OQ Test Box, voltmeter and current meter as indicated in figure 4-12.

4-8 100-2754C 10/08

 System Checkout

Voltmeter Current Meter

VDC mA DC
PowerPac Universal
Power Supply IQ/OQ Test Box

(+) (-)(+)
500 80
Ohms Ohms

(-) (+) (-) (+) (-) (+) (+) (-) (+) (-)

Figure 4-12: Meter Setup for 500 Ohms

3. Turn on the power supply.
4. Wait until the Home screen is displayed. See figure 4-3.
5. Using the Function key select Methods.
6. Using the Function key select Methods...New...Edit, then create the following Method. See table 4-3.

Note: Press Edit to accept the values and press the Down key to create an empty step. This method contains
nine steps.

Table 4-3: 500 Ohms Method

Step Constant Limit V Limit A Limit W Time
S1 200 V 2500 mA 500 W 00:01h
S2 60 mA 500 V 500 W 00:01h
S3 20 W 500 V 2500 mA 00:01h
S4 700 mA 500 V 500 W 00:01h
S5 50 V 2500 mA 500 W 00:01h
S6 500 V 150 mA 500 W 00:01h
S7 2500 mA 500 V 100 W 00:01h
S8 500 W 200 V 2500 mA 00:01h
S9 250 W 500 V 2500 mA 00:01h

Note: Steps S6, S7, and S8 are crossover tests. The unit will be limited by another parameter before it
reaches the setpoint on the controlled parameter.

---------------------------------------------------------------------------------------------------------------------------------

100-2754C 10/08 4-9

System Checkout

7. Press Save to save the Method.

8. Press the Start key to run the method.
9. Verify the power supply and the meters values are within the ranges as indicated in the Voltage, Current, and
Power Specification Table. See Table 4-4.
10. If values are not within specification, then the PowerPac Universal needs to be calibrated. See Section 7.3.
Table 4-4:Voltage, Current, and Power Specification Table
Step At 500 Ohms Limited by Voltage Range Current Range Wattage Range
S1 200 V 196 - 204 V
S2 60 mA 55 - 65 mA
S3 20 W 19.6 - 20.4 W
S4 700 mA 686 - 714 mA
S5 50 V 49 - 51 V
S6 150 mA 145 - 155 mA
S7 100 W 98 - 102 W
S8 200 V 196 -204 V
S9 250 W 245 - 255 W

Note: The Power is obtained by multiplying the Current times the Voltage value read by the meters.

4-10 100-2754C 10/08

 System Checkout

PowerPac Universal
Service Repair and Test Certification

Customer: Instrument Serial Number:

Case Number: AC Input Voltage: ‰ 100v ‰ 120v ‰ 220v ‰ 240v

Test Specification Results

Startup Proper Initialization ‰ Pass ‰ Fail

Firmware Version _____________

Instrument Function Power On Test ‰ Pass ‰ Fail

Rapid Resistance Change Detection Test with RRCd On ‰ Pass ‰ Fail
Rapid Resistance Change Detection Test with RRCd Off ‰ Pass ‰ Fail
Overload Short Circuit Test ‰ Pass ‰ Fail
Power Failure Detection Test with PFd On ‰ Pass ‰ Fail
Power Failure Detection Test with PFd Off ‰ Pass ‰ Fail

System Checkout At 80 Ohms

Display 195 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 200 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 20 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 1800 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 20 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 500 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 100 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 80 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 250 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail

At 500 Ohms
Display 500 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 60 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 20 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 700 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 50 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 150 mA Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 100 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 200 V Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail
Display 250 W Voltage Meter______ Current Meter______ ‰ Pass ‰ Fail

The above referenced instrument has been serviced, calibrated and tested and meets all performance specifications.

Bio-Rad Service_____________________________________ Date_________________

100-2754C 10/08 4-11

 Preventative Maintenance

Section 5
Preventative Maintenance

5.1 PowerPac™ Universal Preventative Maintenance

The PowerPac™ Universal requires only minimal preventative maintenance. The procedures below provide
instructions for maintaining PowerPacs that are regularly used, infrequently used and for long term storage.
The PowerPac™ Universal preventative maintenance should be performed as part of the PowerPac™ Univer-
sal maintenance procedure.

5.1.1 Daily Maintenance

1. Unplug the PowerPac™ Universal unit.
2. Use a damp cloth to wipe down the outer case of the PowerPac. Avoid wetting the power switch, power entry mod-
ule, output jacks on the front, and rear fan vent of the instrument.

5.1.2 Overnight Storage

The complete system should always be turned off at the end of the work day, when not in use, or if not being
used for a period of more than two hours.

5.1.3 Long-term Storage

The power to the complete system should always be off and stored in a cool, dry environment if the system
is not being used for a long period of time. Follow the Daily Maintenance procedure before long term stor-
age. The unit should be stored in a plastic bag for dust particle protection.

5.1.4 PowerPac™ Universal Preventative Maintenance

1. Turn off the unit and disconnect the power cord.
2. Disconnect all cables from the unit’s output jacks.
3. Use a damp cloth to wipe down the outer casing. Avoid wetting the power switch, power entry module, output
jacks on the front, and rear fan vents of the instrument.
4. Clean all connection jacks with a cotton swab and isopropanol alcohol.
5. Allow to unit to air dry before setup and usage.
6. Perform the System Checkout section to verify instrument performance.

100-2754C 10/08 5-1

Preventative Maintenance

PowerPac™ Universal Power Supply

Preventative Maintenance Report

Customer: Case Number:

Performed by: Serial #: Date:

Component Checked Replaced Cleaned

Casing
Output Jacks
Keypad
Firmware version #
Display Function
Power-On Test
Rapid Resistance Change Detection Test
Overload Short Circuit Test
Power Failure Detection Test
Constant Voltage, Current, and Power Test at 80 Ohms
Constant Voltage, Current, and Power Test at 500 Ohms

Comments:

The PowerPac™ Universal has been serviced for preventative maintenance and meets all of the specifications
for performance.

Performed by:____________________________________________ Date__________________________

Bio-Rad Service Engineer

5-2 100-2754C 10/08

 Removal and Replacement

Section 6
Removal and Replacement

6.1 Introduction
This section of the manual provides instructions on the proper way to remove and replace field replacable parts
and assemblies. Alignment procedures that should be performed when a field replacable assembly is replaced
are listed in this section in the Replacement / Adjustment Matrix. The procedures indicated should be per-
formed in the order they are listed in the matrix.

Note: Removal and replacement procedures which are obvious from the appearance of the unit are not
included. Unless otherwise specified, following the removal instructions in reverse order will provide the
correct procedure for replacing the assembly.

6.2 Replacement / Adjustment Matrix

The following table shows what adjustment or checkout procedures must be performed after a field replacable
assembly is replaced. The calibration procedures must be performed even if the original assembly is being
reinstalled in the same unit. They must be performed in the order specified.

F ie ld -R ep la ca b le As sy. Ad ju st m en t / C ali b r at io n S ect i on

Bur n -i n Pr oc e du re a nd Po wer Pa c U ni v er s a l
M ai n Bo ar d 7 .4 an d 7.3
P o w e r S u p p l y C a l i b ra t i o n

6.3 Removal and Replacement Procedures

6.3.1 Tools Required

• 3/16” slotted screwdriver
• Phillips screwdriver

6.3.2 Front Panel/Top Cover Removal

1. Remove two screws holding the cover. See figure 6-2
2. Insert a thin, flat blade screwdriver in the slots of the bottom case and push in to release the top cover tabs from the
bottom case latches. See figure 6-1.

100-2754C 10/08 6-1

Removal and Replacement

Insert Flat Blade Screwdriver

Figure 6-1: Power Supply Rear View

3. Lift cover and unplug Front Panel ribbon cable on connector J3, located on the Main PCB.
4. Remove the Top Cover from the bottom casing.
5. Install a new Top Cover.

Front/Top/Bottom Cover
10011691

Fan Assembly
Display PCB 10011692
10011687

Main Board
10011686 Temperature Sensor
10011688

Connector J6

Screws

Figure 6-2: Removing Covers

6-2 100-2754C 10/08

 Removal and Replacement

6.3.3 Main Board Removal (10011686)

1. Remove Top Cover as indicated in Section 6.3.2. Steps 1 to 5.
2. Unplug Fan connector J4 on Main Board. Lift and remove Fan assembly.
3. Using proper Electrostatic Discharge (ESD) precautions such as a wrist strap and ground mat, remove the Main
Board.
4. Install a new Main Board.
5. Set serial number per Section 7.5.
6. Burn in Main Board per Section 7.4.
7. Calibrate PowerPac Universal per Section 7.3.

6.3.4 Temperature Sensor Removal (10011688)

1. Remove Top Cover as indicated in Section 6.3.2. Steps 1 to 5.
2. Unplug Temperature Sensor connector J4 on Main Board. Lift and remove Temperature Sensor.
3. Install a new Temperature Sensor.

6.3.5 Firmware Removal (10011689)

1. Remove Top Cover as indicated in Section 6.3.2. Steps 1 to 5.
2. Locate the Firmware Chip at U11 on the Power Board.
3. Using proper Electrostatic Discharge (ESD) precautions such as a wrist strap and ground mat, remove the IC from
the U11 socket.
4. Install the replacement Firmware chip. Check for proper orientation and seating. The dot on the IC matching the
arrow on the socket. See figure 6-3.

Arrow

Dot

Figure 6-3:

6.3.6 Fan Assembly Removal (10011692)

1. Remove Top Cover as indicated in Section 6.3.2. Steps 1 to 5.
2. Unplug Fan connector J14 on Main Board. Lift and remove Fan assembly.
3. Install a new Fan Assembly.

100-2754C 10/08 6-3

Removal and Replacement

6.3.7 Display Board Removal (10011687)

1. Remove Top Cover as indicated in Section 6.3.2.
2. Place Top Cover a flat surface. See figure 6-4.
3. Remove two screws holding the Display board. Remove Display board and remove Keypad.
4. Install Keypad and then install a new Display Board.

Display Board
10011687
Remove
Screws

Top Cover

Figure 6-4: Display Board

6.3.8 Fuse Removal

1. Turn around the PowerPac Universal so the back is accessible.
2. Insert a flat blade screwdriver to press the tabs on the side of the Fuse Holder toward each other. This will release
the Fuse Holder. See figure 6-4.
3. Remove the 6.3 A, 250VAC, 5x20 mm fuses (10011693). Install new fuses.

Fuse Holder Press

Here

Figure 6-5: Fuse Removal

6-4 100-2754C 10/08

 Adjustment and Calibration

Section 7
Adjustment and Calibration

7.1 Introduction
This section of the manual provides instructions for adjusting, calibrating, and maintaining the PowerPac™
Universal power supply.

7.2 Adjusting the Screen Contrast

1. Turn on the power supply.
2. Wait until the “Home” screen is displayed.
3. Press the Setup key, then press the Function key to select Panel
4. Using the Function key select Contrast.
5. Use the Alphanumeric keypad to enter 105 to adjust the screen contrast, then use the Function key to select Ok.
6. Press the Stop/Home key to go to “Home” screen.

Note: The minimum contrast number is 80 and the maximum is 110.

7.3 PowerPac Universal Power Supply Calibration

The PowerPac Universal power supply has been calibrated by automated equipment at the factory. If the unit
is out of calibration, or repair has been made to the main board, it is possible to recalibrate the power supply
using an IQ/OQ Test Box, and a PDA with the maintenance commands enabled.

7.3.1 Tools and Materials

• IQ/OQ Test Box (10011694)
• Calibrated Fluke True RMS Multimeter Model 189 or equivalent (0.1% DCV and 0.15% DC mA accuracy)
• Banana Plug Adaptor (920-7369)
• High Voltage Test Cable Set (800-0838)
• PDA with Palm OS version 4.0 or higher, and 16 MB memory minimum
• PowerPac Remote Control Software (164-5067)

7.3.2 Installing the PowerPac Remote Software

The file PowerPacRemote.prc is automatically copied onto the PC when PowerPac data transfer software is
installed. With the PowerPac data transfer software running. PowerPacRemote.prc can be beamed to the
PDA from the File menu.

If the PowerPacRemote.prc software in not copied automatically onto the PC, then do the following:
1. Place the CD in the CD drive of a computer with an infrared (IR) port. If installation starts automatically, cancel it.
2. Double click on the My Computer desktop icon and open the CD drive.
3. Right click on the CD drive to open or explore it.
4. Copy the file PowerPacRemote.prc to the PC hard drive.

100-2754C 10/08 7-1

Adjustment and Calibration

5. Beam the file to the PDA.

7.3.3 Enabling the Maintenance Command

To enable the Maintenance Command, the PowerPacRemote.prc needs to be installed in the PDA. See
Section 7.3.2.
1. On the PDA, open up the SECURITY category and set the password to Q25701.

Figure 7-1: Security Icon

2. After setting up the password, open up the PowerPac Remote application and make sure the Maintenance option
is available. See figure 7-3.

Figure 7-2: PowerPac Remote Icon

Bio-Rad Laboratories
PowerPac Remote Control

Select / Edit Methods...

Run Data

Maintenance

Figure 7-3: Maintenance Option

7-2 100-2754C 10/08

 Adjustment and Calibration

7.3.4 Calibrating The PowerPac Universal

Two points are needed to calibrate the power supply. The 80 ohms Load is the first point and the 500 ohms
Load is the second point.
1. Setup the power supply, IQ/OQ Test Box, voltmeter, and current meter as indicated in figure 7-4 for the first cali-
bration point.
2. Power up the power supply and meters.
3. On the PowerPac Universal, use the Function Keys and select Manual
4. Using the Alphanumeric Keypad enter 200 to set the Constant Voltage to 200. If the unit crosses over to current
mode control, select a lower voltage until the unit stays in voltage mode control.
5. Press the Start key to run the unit.

Note: Run the power supply for a maximum of 30 seconds then press the Stop button.

6. Note the current measured and the voltage used. If the meter reads more than 2500mA, select on step 4 a lower
voltage until the meter reads 2500mA or below.
7. Enable the Maintenance Command as indicated in Section 7.3.2.
8. Click on Maintenance button, then select Commands...Calibrate high C
9. Enter the voltage used as the Command Parameter, and the current measured in milliamps as the Command
Parameter 2.

Note: For the CommandParameter 2, round off the current measured to a whole number, do not enter
decimals.

10. Press Beam Command and hold the PDA so that it can communicate with the PowerPac Universal. The PowerPac
will then perform a brief run, and measure how much current it reads from its data acquisition system. Observe the
DVM measuring current during this run, and insure that the current measured is within 10 mA of the second
parameter entered in step 6. If it is not, repeat steps 3 to 8.
11. A double Beep will sound three times indicating that the parameters have been read.

Current Meter
mA DC
PowerPac Universal
Power Supply
IQ/OQ Test Box

500 80
Ohms (+)
(-) Ohms

(-) (+) (+) (-)

Figure 7-4: Calibration Setup with 80 Ohms Load

100-2754C 10/08 7-3

Adjustment and Calibration

12. Setup the power supply, IQ/OQ Test Box, voltmeter, and current meter as indicated in figure 7-5 for the second
point.
13. On the PowerPac Universal, use the Function Keys and select Manual.
14. Using the Alphanumeric Keypad enter 20 to set the Constant Voltage to 20.
15. Press the Start key to run the unit.

Note: Run the power supply for a maximum of 30 seconds then press the Stop button.

16. Note the current measured and the voltage used.

17. Enable the Maintenance Command as indicated in Section 7.3.1.
18. Click on Maintenance button, then select Commands...Calibrate Low C.
19. Enter the voltage used as the Command Parameter, and the current measured in milliamps as the Command
Parameter2.

Note: For the CommandParameter 2, round off the current measured to a whole number, do not enter
decimals.

20. Press Beam Command and hold the PDA so that it can communicate with the PowerPac Universal. The PowerPac
will then perform a brief run, and measure how much current it reads from its data acquisition system. Observe the
DVM measuring current during this run, and insure that the current measured is within 2 mA of the second param-
eter entered in step 17. If it is not, repeat steps 14 to 20.
21. A double Beep will sound three times indicating that the parameters have been read.
22. Select Command... Use Calibrated C command, then select Beam Command, and hold the PDA so it can com-
municate with the PowerPac Universal. This completes the calibration process.
23. Check the calibration by performing the Constant Voltage and Current Test. See Section 4.7.

Current Meter
mA DC

PowerPac Universal
Power Supply IQ/OQ Test Box

500 80
Ohms Ohms
(+) (-)

(+) (-)
(-) (+)

Figure 7-5: Calibration Setup with 500 Ohms Load

7-4 100-2754C 10/08

 Adjustment and Calibration

7.4 Burn-In Procedure

This procedure is recommended if the main board has been replaced.
1. Set the PowerPac Universal as indicated in figure 7-6.
2. Turn on the power supply.
3. Wait until the Home screen is displayed.
4. Using the Function key select Manual.
5. Select CONSTW. Using the Alphanumeric Keypad enter 500 to set the Constant Wattage to 500
6. Press the Edit key twice.
7. Select HRS. Using the Alphanumeric Keypad enter 100 to set the running time to an hour.
8. Press the Start key to run the unit. The run will stop in an hour.
9. Perform System Checkout. See Section 4.

Burn-In Load

PowerPac Universal

Figure 7-6: Burn-in Setup

Note: The Burn-In Load is a two 40 ohms, 300 Watt, resistors in series giving a total resistance of 80 ohms.

100-2754C 10/08 7-5

Adjustment and Calibration

7.5 Set Serial Number

This command allows setting of the Serial Number of the unit. When a board replacement is done in the
field, the serial number of that board should be set to match the last five digits of the serial number on the
nameplate label, found on the bottom of the unit.
1. Enable the Maintenance Command as indicated in Section 7.3.3.
2. Select Maintenance option and the Maintenance screen will open.
3. Select the Command option and a pull down menu will show.
4. Select Set Serial Number and enter the new Serial Number.

Note: If the Serial Number has already been set on the board, it is necessary to reset the serial number to
00000 before setting the new value. This will prevent accidentally setting an inappropriate serial number.

5. Hold the PDA so that the Power Supply IR port is lined up with PDA IR port.
6. Select Beam Command and wait until the command has been transmitted by the PDA and received by the PowerPac
Universal.

7-6 100-2754C 10/08

 Troubleshooting

Section 8
Troubleshooting

8.1 Introduction
The troubleshooting information in this section will help to identify and diagnose operating difficulties and com-
ponent failures in the PowerPac™ Universal Power Supply. This section may be expanded to include addi-
tional troubleshooting aids as service center experience identifies recurrent problems and appropriate
diagnostic processes.

If after reading through this manual, you find that you need additional assistance in resolving a problem, you
may contact our Technical Service Department by phone at 800-424-6723, or by FAX at 510-741-5802.

8.2 Troubleshooting the PowerPac™ Universal

This section provides troubleshooting information in three parts. The first part lists Error Messages, followed by
a troubleshooting guide that uses a Problem, Cause, Solution format for determining the root cause of prob-
lems.

Caution: The extruded heatsinks of the main FETs at Q6, 7, 12, and 13 of the power converter board are
connected to power ground and are not safe to touch while the unit is plugged in even when the power switch
is turned off. The push-on heatsink od Q1, U1, and U3 are NOT isolated and should not be touched while the
unit is plugged in even if the power switch is turned off. The capacitors C11, 12, 57, and C58 stay charged for
a long time after turnoff. Discharge them before commencing work on the board.

8.2.1 Error Messages

Error Messages Cause Solution

ERROR STOP: CODE 01 - NO LOAD 1. Electrophoresis cell no 1. Make sure all electrical con-
DETECTED connected to the power nections are making good
supply contact and the cables and
wire electrodes are in good
2. the current load is less
shape.
than 1mA.
2. Verify buffer levels are appro-
priate.
3. Verify the electrophoresis
application power require-
ments match PowerPac Uni-
versal output range.

100-2754C 10/08 8-1

Troubleshooting

Error Messages Cause Solution

ERROR STOP: CODE 02 - OVER CURRENT 1. Accidental shorting of 1. Make sure all electrical con-
the outlet leads. nections are making good
contact, and the cables and
2. Shorting due to wrong
wires electrodes are in good
connections.
shape.
2. Verify buffer levels are appro-
priate.
ERROR STOP: CODE 03 - OVER VOLTAGE 1. Connection to an external 1. Correct problem and press the
source or control cir- CONTINUE soft key to con-
cuitry problem. tinue the run.
2. If the problem continues,
cycle power and restart the
run. If the problem persists,
check the power converter
feedback loop, and the power
converter control chip.
ERROR STOP: CODE 07 - RUN POWER AC power was interrupted dur- To continue a run after a power fail-
FAILURE ing a run, and the run is termi- ure make sure to activate the PFd
nated because the Power Failure mode in the SETUP window prior to
detection (PFd) is OFF. each run.
ERROR STOP: CODE 08 - REGULATION Control circuitry problems. 1. Press the RESET key to clear
ERROR the screen, then restart the
run.
2. If the problem continues,
cycle power and restart the
run. If the problem persists,
check the power converter
feedback loop, and the power
converter control chip.
ERROR STOP: CODE 09 - RAPID CHANGE 1. Loose output connections 1. Verify all electrical connec-
IN RESISTANCE leading to intermittent tions.
connection to the loads.
2. Pause power supply prior to
2. Cells added or removed adding or removing electro-
during the run. phoresis cells.
3. Change in buffer levels. 3. Verify buffer levels are appro-
priate.

Note: Certain applications exhibit

intrinsic fluctuations in resistance
(e.g., Dcode). If this is the case,
the change in resistance
detection feature can be disable
to allow uninterrupted completion
of the run.

8-2 100-2754C 10/08

 Troubleshooting

Error Messages Cause Solution

ERROR STOP: CODE 11 -GROUND LEAK Insulation failure in the electrical 1. Check electrical connections,
connections made outside the electrophoresis cell, and
power supply has caused a cur- chiller system for leaks. Ver-
rent flow that is not desirable ify that the electrophoresis
and could be harmful. cell rests on an insulated and
dry surface.
2. Check power source connec-
tions. Additional capacitance
to ground from external EMC
filters or uninterruptible
Power Supplies can cause
excessive ground currents.
ERROR STOP: CODE 12 -REGULATION Improper load, or connection to 1. Press Reset and restart the
ERROR a voltage source run.
2. If the problem continues,
cycle power and restart the
run. If the problem persists,
contact Bio-Rad Technical
support.
ERROR STOP: CODE 13 - PERM MEM Internal circuitry problems Cycle power and restart run. If prob-
ERROR lems persists, replace the processor
chip, the flash memory, or RAM.
ERROR STOP: CODE 17 - OVERTEMPERA- The temperature inside unit Wait until the temperature inside the
TURE ERROR exceeds 58°F. unit decreases.
Temperature Sensor damaged. Replace Temperature Sensor
(10011688)
Main Board damaged. Replace Main Board (10011686)

8.2.2 Troubleshooting Guide

Problem Cause Solution

No display/lights/fan. 1. No AC power. 1. Check if the Power Pac is
unplugged, or problem
2. Blown fuse.
with AC power source, or
3. Contrast setting. power switch is in OFF
position.
2. Replace the fuse. See Sec-
tion 6.9.
Repeated blown fuses. Hardware failure. Replace Main PCB (810011686)
Display freezes at Power-On C97 leads are broken off from main Replace C97 (900-2417)
PCB

100-2754C 10/08 8-3

Troubleshooting

Problem Cause Solution

Leads from the cell are not long enough
to fit the output jacks.
Output terminals for the PowerPac
Universal are recessed 16 mm to
meet safety regulations. Some leads
are not long enough to make electri-
cal connection.
Use the PowerPac Adaptor (165-
5061), which accommodates most
standard 4 mm banana plugs to
make secure electrical connection
Note: Use of this PowerPac
Adaptor voids EN61010 safety
provisions.

8.2.3 Test Point List

Test Point Number Measurement Purpose

TP1 Protective Ground. Check leakage current circuit.
TP2 Power Ground. Floating ground for use with converter section. Use only ±
1kV rated differential probes only.
TP3 +12V DC supply.
TP4 -12V DC supply.
TP5 +5V DC supply.
TP6 PWM Controller Ramp. U5 PWM circuit operation.
TP7 PWM Output #1. U5 PWM circuit operation.
TP8 PWM Output #2. U5 PWM circuit operation.
TP9 FET Drain Current. Current feedback to U5 from T1.
TP10 Drain Voltage Aux Supply. Check turn-on, turn-off, snubber operation. Use only ± 1kV
rated differential probes only.
TP11 Autorange Ground. Check autorange switching of voltage doubler. Use only ±
1kV rated differential probes only.
TP12 Autorange Positive. Check autorange switching of voltage doubler. Use only ±
1kV rated differential probes only.
TP13 Drain Voltage Q6 and Q12. Check turn-on, turn-off, snubber operation. Use only ± 1kV
rated differential probes only.
TP14 Drain Voltage Q7 and Q13. Check turn-on, turn-off, snubber operation. Use only ± 1kV
rated differential probes only.
TP15 Positive Output Voltage. Output voltage check.
TP16 Voltage Sense Node. Check voltage divider, feedback network.
TP17 Current Sense to A/D. Check current sense circuit, A/D counts.
TP18 Voltage Control. Check D/A control.
TP19 Power Good Reference. Check reference for switching out soft start resistor R54.
TP20 Reference Aux Supply. Check feedback of auxiliary supply.
TP21 PWM Controller Clock. U5 PWM circuit operation.
TP22 Negative Bias Voltage. Check negative bias on voltage control input to converter.

8-4 100-2754C 10/08

 Troubleshooting

Test Point Number Measurement Purpose

TP23 Output Center Node. Check balance of two series converter stages.
TP24 Negative Output Voltage. Reference for TP15.
TP25 High Voltage Power. Rectified DC Voltage to converter. Use only ± 1kV rated
differential probes only.
TP26 IrDA Data Out. Check IrDA output to transceiver.
TP27 IrDA Data In. Check IrDA input from transceiver.
TP28 LCD Contrast PWM. PWM signal to generate negative bias for LCD contrast.
TP29 LCD Contrast Voltage DC voltage to LCD for contrast control.
TP31 LCD Backlight Voltage Voltage to LCD backlight (around -4.2 VDC).
TP32 Processor Basic Output. Test pin - if square wave, then processor is functioning.
TP33 Aux Supply Power Ground. Reference for TP10. Use only ± 1kV rated differential
probes only.

100-2754C 10/08 8-5

 Parts

Section 9
Parts Information

9.1 Introduction
This section contains parts lists and associated information. It provides instructions for ordering and returning
defective parts. This section also identifies parts that are field replacable.

9.2 Parts Orders - US Domestic Operations

Parts may be ordered through our Service Parts department. You can reach the Service Parts department dur-
ing Pacific time regular office hours by calling 1-510-741-5038, 5058, 5071 or 5067. You can help to make pro-
cessing your order more efficiently by having the following information before you call:
• The part number(s) or catalog number(s) of the parts you want to order
• Shipment information
• Your account or inventory location number

9.3 Parts Orders - International Subsidiaries

The procedures for ordering parts vary from region to region outside the United States. Please contact your
Bio-Rad Export Sales Representative through your regular sales and service channels.

9.4 Returning Defective Parts

Defective assemblies returned for repair are an important part of the service logistics and inventory control pro-
cess. Returned assemblies are refurbished, tested, and returned to service stock. Maintaining the effective-
ness and efficiency for this process enables us to deliver the high standard of service that our customers
expect, at reasonable cost that allows us to remain competitive.

You are an integral part of our inventory process. When you return parts or assemblies to Bio-Rad to be
repaired, please attach a tag to each assembly. The tag should contain the following information:
• Model and serial number of the unit from which the part was removed
• The date of removal
• A description of the problem or symptoms exhibited (if you could not find the problem, describe what the
user reported and specify “CND - Can Not Duplicate”)
• The part number or catalog number of the part being returned
• Your name and other identification information

This information will help our service centers to make repairs efficiently. When you receive replacement parts,
save the packaging material for returning the defective part for repair. Many of the parts are delicate and
expensive; extra attention to packaging will pay off in less damage to parts during shipment.

Note: Additional procedures and information may be needed for the return of defective parts from interna-
tional operations. These procedures vary depending on your location.

100-2754C 10/08 9-1

 Parts

9.5 Recommended Spares

The appropriate quantity for each of the PowerPac™ Universal power supply spares will vary depending on the
total quantity of instruments in your installed base. A quantity of 1 for each field replacable part is a good start-
ing point.

Recommended Spare List

D esc rip t io n Par t Nu m b er Ph o to
Main PCB Assembly 10011686

Display PCB Assembly 10011687

Temperature Sensor 10011688

Firmware IC 10011689
(U11)

100-2754C 10/08 9-2

 Parts

Recommended Spare List

D esc rip t io n Par t Nu m b er Ph o to
Keypad 10011690

Universal Covers 10011691

(Includes front, top, and bottom
covers)

Fan Assembly 10011692

Fuse 10011693
6.3 A, 250VAC, 5x20mm

100-2754C 10/08 9-3

 Parts

9.6 Service Tools

The following tools are recommended for testing and servicing.

Recommended Tools List

D esc rip t io n Par t Nu m b er Ph o to
Fluke True RMS Multimeter Order from
Model 189 website at
www.fluke.com

Burn-in Box
(Includes two 40 ohms, 300 2AWR 4000-2S
Watt, resistors in series to give a
total resistance of 80 ohms)
Order from
website at
www.avtron.com

High Voltage Test Cable Set 800-0838

Banana Plug Adaptor 920-7369

100-2754C 10/08 9-4

 Parts

Recommended Tools List

D esc rip t io n Par t Nu m b er Ph o to
IQ/OQ Test Box 10011694

9.7 Software

D esc rip t io n Par t Nu m b er Ph o to

PowerPac Universal Power 164-5067
Supply Data Transfer Software

100-2754C 10/08 9-5

 Drawings

Section 10
Drawings

10.1 Introduction
This section contains schematics and assembly drawings for the PowerPac™ Universal Power Supply. These
drawings are intended to be used as aids for troubleshooting and parts identification.

10.2 System Diagrams

10.2.1 Power Block Diagram

10.3 Assembly Drawings and Schematics

10.3.1 Schematics
• PowerPac Universal Power Converter E-8686 1 sheet
• Front Panel, PowerPac Universal E-8693 1 sheet
• IQ/OQ PCB E-9861 1 sheet

10.3.2 Assembly Drawings

• PowerPac Universal Assembly 800-8686 1 sheet
• Display Board Assembly, PowerPac Universal 800-8693 1 sheet

100-2754C 10/08 10-1

10-2
Drawings

AC Power -Good PGD Signal to Universal Power Supply System

Detector Network
OUTPUTS
HV Power for Universal
Low-Power Auxiliary DC-DC +12V(S) Power supply Controls
DC
HV AC-DC Rectifier (“Housekeeping”) +5V(S) and Display
and
Converter Network -12V(S) (see note 2 below)
Filtered Capacitor Filter Bank
AC
Filtered
AC NOTE: Output tied in series
120V 0r
240V AC
50-60Hz HV Output(s)
On/Off Control HV AC-DC Rectifier DC Dual Main 5-200V@1.2A
and AC EMI Filter and Capacitor Filter Power Converter 200-500V@2.5A
User Network Bank Circuits 500W Max Pwr Out
Power
Source AC Out Dual 50kHz Output Voltage
In Power PWM Primary and Current Samples
Drive Current
Configure Signals Samples
AC Line
Filter
Autorange
Control Circuit For 120V/240V Main 100kHz PWM Error Amplifier and Set
Operation Control Network Control Circuitry Ref
Volts
Feedback
NOTES: 1. For circuit details of system elements
shown in this drawing, see Bio-Rad schematic Error Voltage
E8686. Voltage Converter Shutdown
2. (S) => designates voltage is referenced Control
to output ground potential.
PowerPac Universal Diagram
Bio-Rad Laboratories

100-2754C 10/08
 Appendix

Section 11
Appendix

11.1 PowerPac Data Transfer Software

11.1.1 Installing the Data Transfer Software onto a PC

1. Place CD in the CR drive. Installation will run automatically.
2. If installation does not run automatically follow steps 3 to 6.
3. Double click on the My Computer desktop icon.
4. Select the CD drive by double clicking.
5. Double click on the Setup.exe.
6. Follow the instructions for PowerPac data transfer software installation.

11.1.2 Installing the Remote Software onto a PC

1. The file PowerPacRemote.prc is automatically copied onto the PC when the PowerPac Data Transfer software is
installed. With PowerPac Data Transfer software running, PowerPacRemote.prc can be beamed to the PDA from
the File menu. Alternatively, follow steps 2 to 6.
2. Place CD in the CD drive of a computer with an infrared port. If installation starts automatically, cancel it.
3. Double click on the My Computer desktop icon. and open the CD drive.
4. Right click on the CD drive to open or explore it.
5. Copy the file PowerPacRemote.prc to the PC hard drive.
6. Beam the file to the PDA.

11.1.3 Infrared (IR) Port

The infrared (IR) port is needed for file transfer as shown in the diagram below:

Method File Transfer

PDA
Data File Transfer
PowerPac
Universal Data File Transfer
Power
Supply

Data File Transfer

PC

Figure 11-1: File Transfer Diagram

100-2754C 10/08 11-1

Appendix

11.2 Maintenance Mode Commands

11.2.1 Enabling the Maintenance Command

1. On the PDA, open up the SECURITY category and set the password to Q25701.

Figure 11-2: Security Icon

2. After setting up the password, open up the PowerPac Remote application and make sure the Maintenance option
is available. See figure 7-3.

Figure 11-3: PowerPac Remote Icon

Bio-Rad Laboratories
PowerPac Remote Control

Select / Edit Methods...

Run Data

Maintenance

Figure 11-4: Maintenance Option

11.2.2 Set Contrast

When this setting is done through the front panel only values between 80 and 110 can be used. However
when using the Set Command, the contrast can be set to any value, which can cause the display to be blank
(with a number that is too low), or to have all dots darkened (with a number that is too high). Care should be
taken to choose values that are between 80 and 110, so that the display can be read.

11-2 100-2754C 10/08

 Appendix

1. Enable the Maintenance Command as indicated in Section 11.1.1.

2. Select Maintenance option and the Maintenance screen will open.
3. Select the Command option and a pull down menu will show.
4. Select Set Contrast and select a value between 80 and 110.
5. Hold the PDA so that the Power Supply IR port is lined up with PDA IR port.
6. Select Beam Command and wait until the command has been transmitted by the PDA and received by the Power-
Pac Universal.

11.2.3 Set Serial Number

This command allows setting of the Serial Number of the unit. When a board replacement is done in the
field, the serial number of that board should be set to match the last five digits of the serial number on the
nameplate label, found on the bottom of the unit.
1. Enable the Maintenance Command as indicated in Section 11.1.1.
2. Select Maintenance option and the Maintenance screen will open.
3. Select the Command option and a pull down menu will show.
4. Select Set Serial Number and enter the new Serial Number.

Note: If the Serial Number has already been set on the board, it is necessary to reset the serial number to
00000 before setting the new value. This will prevent accidentally setting an inappropriate serial number.

5. Hold the PDA so that the Power Supply IR port is lined up with PDA IR port.
6. Select Beam Command and wait until the command has been transmitted by the PDA and received by the Power-
Pac Universal.

11.2.4 Restore Factory Defaults

The Restore Factory Defaults command is not activated at this time.

11.2.5 Stop Power Supply

This command stops the run in process. If performs the same function as the “Stop/Home” key when the unit
is running.
1. Make sure that the Power Supply is running a process.
2. Enable the Maintenance Command as indicated in Section 11.1.1.
3. Select Maintenance option and the Maintenance screen will open.
4. Select the Command option and a pull down menu will show.
5. Hold the PDA so that the Power Supply IR port is lined up with PDA IR port.
6. Select Stop Power Supply then select Beam Command wait until the command has been transmitted by the PDA
and received by the PowerPac Universal. The run should be terminated.

11.2.6 Set PFd

The PFd can not be set using the PDA.

100-2754C 10/08 11-3

Appendix

11.2.7 Calibrate Low C

This Command provide a method for manual calibration of the unit. In this command the Low Current value
is used.
1. Setup the power supply, IQ/OQ Test Box, voltmeter, and current meter as indicated in figure 7-4.
2. Power up the Power Supply and meters.
3. On the PowerPac Universal, use the Function Keys and select Manual
4. Using the Alphanumeric Keypad enter 200 to set the Constant Voltage to 200. If the unit crosses over to current
mode control, select a lower voltage until the unit stays in voltage mode control.
5. Press the Start key to run the unit.

Note: Run the power supply for a maximum of 30 seconds.

6. Note the current measured and the voltage used.

7. On the PDA enable the Maintenance Command as indicated in Section 11.1.1.
8. Select Maintenance option and the Maintenance screen will open.
9. Select the Command option and a pull down menu will show.
10. Click on Maintenance button, then select Commands...Calibrate Low C
11. Enter the voltage used as the Command Parameter, and the current measured in milliamp as the Command
Parameter 2.

Note: On Command Parameter2 enter only the whole numbers, do not enter decimals.

12. Press Beam Command and hold the PDA do that it can communicate with the PowerPac Universal. The Power-
Pac will then perform a brief run, and measure how much current it reads from its data acquisition system. Observe
the DVM measuring current during this run, and insure that the current measured is within 10 mA of the second
parameter entered in step 7. If it is not, repeat steps 4 to 8.
13. Select Command... Use Calibrated C command, then select Beam Command, and hold the PDA so it can com-
municate with the PowerPac Universal. This completes the calibration process.

11.2.8 Calibrate High C

This Command provide a method for manual calibration of the unit. In this command the High Current value
is used.

1. Setup the power supply, IQ/OQ Test Box, voltmeter, and current meter as indicated in figure 7-4.
2. Power up the Power Supply and meters.
3. On the PowerPac Universal, use the Function Keys and select Manual
4. Using the Alphanumeric Keypad enter 200 to set the Constant Voltage to 200. If the unit crosses over to current
mode control, select a lower voltage until the unit stays in voltage mode control.
5. Press the Start key to run the unit.

Note: Run the power supply for a maximum of 30 seconds.

11-4 100-2754C 10/08

 Appendix

6. Note the current measured and the voltage used.

7. On the PDA enable the Maintenance Command as indicated in Section 11.1.1.
8. Select Maintenance option and the Maintenance screen will open.
9. Select the Command option and a pull down menu will show.
10. Click on Maintenance button, then select Commands...Calibrate high C
11. Enter the voltage used as the Command Parameter, and the current measured in milliamp as the Command
Parameter 2.

Note: On Command Parameter2 enter only the whole numbers, do not enter decimals.

12. Press Beam Command and hold the PDA do that it can communicate with the PowerPac Universal. The Power-
Pac will then perform a brief run, and measure how much current it reads from its data acquisition system. Observe
the DVM measuring current during this run, and insure that the current measured is within 10 mA of the second
parameter entered in step 7. If it is not, repeat steps 4 to 8.
13. Select Command... Use Calibrated C command, then select Beam Command, and hold the PDA so it can com-
municate with the PowerPac Universal. This completes the calibration process.

11.2.9 Use Calibrated C

After performing Calibrate Low C and Calibrate High C, this command is used to calibrate the slope and
often necessary for accurate current measurments.This calibration is based on two operating points, which
are used to calculate a slope and an offset to be used to correlate counts from the A/D and the output cur-
rent. This command requires no “Command Parameter” so leave them blank. Just beam the command over,
and the PowerPac Universal takes care of the rest of the process, and stores the new calibration parame-
ters.
1. Enable the Maintenance Command as indicated in Section 11.1.1.
2. Select Maintenance option and the Maintenance screen will open.
3. Select the Command option and a pull down menu will show.
4. Select Use Calibrate C command, then select Beam Command, and hold the PDA so it can communicate with
the PowerPac Universal.

100-2754C 10/08 11-5

E8686B.sch-1 - Wed Oct 08 11:17:41 2003
E8693A.sch-1 - Tue Sep 23 09:50:37 2003
E9861A.sch-1 - Wed Aug 13 11:30:05 2003