Life Science Group

PowerPac Basic™
Power Supply

Service Manual

Part Number 100-2474

 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 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

100-2474B 04/03 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 100-2474.

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 100-2474B 04/03
 Revision Control List

Document: PowerPac Basic

Part Number: 100-2474
Date Issued: April 2003

Each page of this manual has the catalog number, revision level and revision date for that page. Subsequent
revisions to a page will be indicated by changes to the revision level and revision date for that page. A sum-
mary of changes for all revisions is listed in the following table.
Pages in this manual are at revision A unless otherwise noted below.

Page Changed
Revision Description Date
Number By
A Release at Revision A SF 09-2002
B 8-1 to 8-6 Updated Sections 8.2 and 8.3 Troubleshooting and SF 04-2003
Error Code List

100-2474B 04/03 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 Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.5 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
1.6 Operating Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2. System Overview

2.1 About this Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.2 Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3 Theory of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3.1 Microcontroller . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2.3.2 Digital Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.3 Safety Shutdown . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
2.3.4 Flash ROM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.5 Display and User Panel Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.6 Power Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.6.1 On/Off Power Control and AC Filter Network . . . . . . . . . . . . . . . . . . . . . 2-3
2.3.6.2 HV AC-DC Rectifier and Capacitor Filter Bank . . . . . . . . . . . . . . . . . . . . 2-3
2.3.6.3 AC Line Auto Range Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.6.4 Main DC to DC Power Converter Circuitry . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3.6.5 Main PWM Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
2.3.6.6 Error Amplifier & Control Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
2.3.6.7 Auxililary DC-DC Converter Network . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
2.3.6.8 Power Good Detector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Section 3. Installation
3.1 Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.2 Product Catalog Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.3 Unpacking the PowerPac Basic™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.4 Setting Up the PowerPac Basic™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3.5 Connecting the PowerPac Basic™ to the Electrophoresis Cell . . . . . . . . . . . 3-1
3.6 Protective Sheet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

100-2474A 09/02 v
Table of Contents

Page
Section 4. System Checkout
4.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.2 Tools and Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3 Checkout Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3.1 Power on Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4.3.2 No Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.3 Overload Short Circuit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.4 Sudden Load Change Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
4.3.5 Auto Power-Up Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.6 Clarostat Model 240C Decade Box Checkout . . . . . . . . . . . . . . . . . . . . 4-3
4.3.7 Voltage and Current Specification Table . . . . . . . . . . . . . . . . . . . . . . . . 4-3
4.3.8 Voltage and Current Output Measurement Setup . . . . . . . . . . . . . . . . . 4-4
4.3.9 100V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
4.3.10 20V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.11 150V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.12 280V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
4.3.13 20V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.14 150V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.15 170V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
4.3.16 290V Constant Voltage Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.17 380 mA Constant Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
4.3.18 300V Burn-In Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7

Section 5. Preventative Maintenance

5.1 PowerPac Basic™ Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.1 Daily Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.2 Overnight Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.3 Longterm Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5.1.4 PowerPac Basic™ Preventative Maintenance . . . . . . . . . . . . . . . . . . . 5-1

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 Exploded View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3.2 Front Panel/Top Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3.3 Top Cover (920-6946) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
6.3.4 Display Board Assembly (800-8683-01) . . . . . . . . . . . . . . . . . . . . . . . . 6-3
6.3.5 Fan (920-6862) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4

vi 100-2474A 09/02
 Table of Contents

Page
6.3.6 Power Converter Board (800-8683-01) . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.7 Fuse (900-7283) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
6.3.8 Dual Insulated Jack (920-6957/ 920-6962) . . . . . . . . . . . . . . . . . . . . . 6-5
6.3.9 Dual Metal Jack (920-6951) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6
6.3.10 Display PCB from Power PCB Removal (800-8683-01) . . . . . . . . . . . 6-7

Section 7. Adjustment and Calibration

7.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Section 8. Troubleshooting
8.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
8.2 Troubleshooting the PowerPac Basic™ Power Supply . . . . . . . . . . . . . . . . . 8-1
8.3 Error Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
8.4 Test Point List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
8.5 LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6

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 Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
9.6 Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7

Section 10. Drawings

10.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2 System Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
10.2.1 Power System 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 System Checkout Test Certification Sheet . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
11.2 Installation Check Sheet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-4

100-2474A 09/02 vii

 Introduction

Section 1
Introduction

1.1 General Information

This manual is the reference to be used for troubleshooting, repair, and maintenance of the PowerPac
Basic™. 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 Basic™. Complete operating instructions are contained in the PowerPac Basic™
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 Basic™ 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 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 certifi-
cation, and create a potential safety hazard. This safety certification does not extend to other equipment or
accessories not EN61010 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.

This unit has two externally accessible over-protection AC power input fuses. The correct fuse must be used
and rated as 2.5A, 250V, 5 X 20 mm, Type T.

100-2474A 09/02 1-1

Introduction

1.4 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.

1.5 Specifications

PowerPac Basic™
Type of output: constant voltage, constant current

Voltage range: 20-300 V, 1 V steps

Current range: 4-400 mA, 1 mA steps

Timer range: 0-999 min

Maximum power: 75 W

Voltage accuracy: +/-2% of reading or 3 volts, whichever is more

Current accuracy: +/-2% of reading or 3 mA, whichever is more

Line regulation: +/- 1% at 300V

Load regulation: +/- 1% with 50% load change

Output drift: +/- 0.5% per hr after 30 min warm-up

Number output jacks: 4 sets

Safety features: No-load detection; ground leak detection; sudden load change detection; overload/short circuit
detection; auto power-up after power failure; over-protection external fuses( 2 Each- 2.5A, 250V, 5 X 20 mm,
Type T)

Regulatory Certification: EN61010, CE (220/240 V only)

Readout stability: Volts +/- 1%, Current +/- 1%

Display functions: volts, current, time remaining if timer set, time elapsed if timer not set

Function modes: constant voltage, constant current, timer, default on: automatic start-up after power failure,
automatic crossover

Input power: 90-264 VAC, 50-60 Hz

Operating Conditions: 4-40 ° C, up to 90% RH, non-condensing.

1-2 100-2474A 09/02

 Introduction

1.6 Operating Conditions

• 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.
• PowerPac Basic™ has passed tests for operation at temperatures between 0 to 40 degrees 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 3-prong, grounded AC outlet, using the 3-prong AC power cord pro-
vided with the power supply.
• Never connect a high voltage output 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 Basic™ into a cold room, the unit can be operated immediately. However, when
removing the unit from the cold room, allow the unit to equilibrate to room temperature for a minimum of 2
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 Basic™. Use of other plugs or banana jacks is done at the operator’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 or metallic ends.

100-2474A 09/02 1-3

 System Overview

Section 2
System Overview

2.1 About this Section

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

2.2 Product Description

The PowerPac Basic™ unit is a 75W electrophoresis variable power supply system that employs state-of-the-
art microcontroller electronics and power conversion networks.

2.3 Theory of Operation

2.3.1 Microcontroller
U11 is a microcontroller of the 8051 family. It is a one-time-programmable device with 256 bytes of RAM
and 16k bytes of ROM. If a software upgrade is needed, the U11microprocessor can be replaced on the
power converter board. The microcontroller has individual programming of pins for various uses. Port 2 is
programmed as all output. Ports 0 and 1 are a mix of input and output pins. When the microprocessor is
reset, all the port pins are tristated, and those that are connected to pullup resistors externally will be high.

The reset signal for the microprocessor, (pin 10 of U11), is derived from the POWER_GOOD signal, by
delaying it in time and inverting its polarity, so that during power application, the unit will be reset. Although
not indicated on the schematic, the reset signal is true when it is low. When it is running, this signal will be
high. Reset is delayed by the 100 millisecond RC filter network (R26 and C44), so that the microprocessor
does not start until the DC power outputs from the auxiliary power converter are stable and in tolerance.
When power goes down, an interrupt is given by the POWER_GOOD signal at pin 14 of U11 (Interrupt 0).
Reset is delayed so that the microprocessor has time before the +5 line from the auxiliary converter fails to
write the needed information to the flash ROM, U16.

W1 pins 1, 2 and 3 are connections on the printed circuit board for possible future use so that the microcon-
troller may be programmed on the PCB if a socket is not used, or to program the OTP chip while on the PCB
to save time. There is provision for loading a header for W1, but it may be absent as programming may be
accomplished by a test fixture, using the test pins on the test fixture.

J7 is a test jack which accommodates a special 2.5 mm stereo connector. This jack is only used for a serial
connection to the microcontroller during manufacturing test. It is not intended to be used for service or other
purposes.

CAUTION! There is no driver interface for J7. Loss of ground isolation could occur using J7 for servicing,
which in turn, could cause safety problems during operation of the unit.

The crystal XT1 runs at 14.7456 MHz, which is convenient for dividing for a baud rate for the test jack. The
value is 216X32X52. For example 9600 baud requires a division by 3 and by 512.

100-2474A 09/02 2-1

System Overview

2.3.2 Digital Control

Rapid control of the output voltage is done in an analog fashion. The fast analog loop corrects for line volt-
age changes, sudden load changes, and to some extent even the ripple on the DC link across capacitors C4
and C5 at 100 Hz or 120 Hz. For current control, or to limit output power, it is necessary for the microproces-
sor to act, and in fact, the voltage control is also under microprocessor loop control. The microprocessor
loop runs much slower, on the order of hundreds of milliseconds.

The voltage and current samples are fed to the microprocessor on a regular basis controlled by an internal
timer in the microcontroller. The readings are taken by the 10 bit Analog to Digital (A/D) converter, U12. The
readings are averaged to reduce noise, and the proper voltage control value is set in the Digital to Analog
(D/A) converter, U13. U13 is a 10 bit D/A. Both of these are serial devices, and share the same serial clock
but have their own chip select to avoid contention, that is, both chips trying to drive a line at the same time.

The input voltage to the A/D is scaled so that 900 counts is 300 volts. Full scale is 341 volts, but if the
sensed voltage is much above 300 volts, the microprocessor will operate the programmed shutdown. Resis-
tors R54 and R55 are used to trim the sensed voltage to exactly 1/3 volt per count, and with C45 also pro-
vide a second filter time constant of 3 microseconds. There is a first filter of 3 microseconds from C12 with
R25 and other loading (see page 1).

Output current is read by channel 1 of the dual A/D, with a scaling such that 400 mA is 800 counts. The
resistance "bank" in series with the output terminals is 4.886 ohms. This is the parallel combination of R66,
R12 and R52, with R52 used as a trimmer element for the bank. This avoids the need for unusual values for
the accurate resistors. At 400 mA, this gives a bank voltage drop of 1.954 volts. Note that 2.5 volts times
800 divided by 1023 is 1.995 volts. R63 and C59 form a 1 millisecond time filter of the current signal, and
there is an additional 47 picofarad capacitor, C64, at the input of Channel 1 of the A/D to filter noise pro-
duced on the PCB. The resistor is shown schematically near U18, but it is physically located near U12.

Voltage and current measurement accuracy are rated at plus or minus 2%. Most of the inaccuracy, 1%, is
due to the tolerance of the reference voltage generated by U14.

It should be noted that the voltage read by the A/D and sent to the microprocessor is the voltage across the
output load and the current sense resistor bank. The voltage reads higher than the load voltage at the A/D,
so the microprocessor subtracts the voltage across the current sense resistor bank to get the corrected load
voltage. This correction is at most 2 volts, or 6 counts of the voltage reading.The value is 216X32X52; for
instance 9600 baud requires a division by 3 and by 512.

2.3.3 Safety Shutdown

There are a number of features to check for various fault conditions in order to shut down or limit the output
power for hardware protection. U9 pin 8 is the SHUTDOWN signal, and is high true. The four open collector
gates of U20 with a 10 k pullup provide a logical OR function, so that any of the inputs to these gates will
cause a shutdown. The first conditions, reset and programmed shutdown, are normal. Reset holds the
power off until the voltages come up, and the microprocessor is functioning properly. Programmed shut-
down is used to keep or turn the power off when the unit is paused, or has not been started.

The other three inputs handle fault conditions. If the microprocessor should fail, it will usually stop giving the
strobes for the display. There is a watchdog timer, U10, which will time out without a strobe in 100 millisec-
onds. Pin 4 will go high, turning on shutdown. If the output current exceeds 540 mA, the signal at pin 3 of
U9 will exceed 2.5 volts and the comparator will give a positive output. This will cause U20 pin 9 to go high,
pin U8 to go low, and the output U19 pin 8 to go high and shut down the output. Finally, if the temperature
on the PCB near the output diode D18 goes above 60 degrees C, the resistance will drop below 1.74 k and
pin 3 will go higher than 2.5 volts, causing a shutdown. This diode is the most thermally sensitive part on the
board, and will run away if the junction temperature exceeds 90 degrees C at full power conditions.

2-2 100-2474A 09/02

 System Overview

2.3.4 Flash ROM

U16A is a nonvolatile flash memory of 1 k bits, which is used to hold information when the power is turned
off. This allows automatic restart of a run after power failure, if enabled. The part is a serial ROM, with its
own chip select line (CS), and shared Data In, Data Out, and Shift Clock.

2.3.5 Display and User Panel Buttons

The output display is strobed with four time periods. Q7 through Q10 are each enabled for 25% of the time
during operation to control the three digits of the 7 segment display and the individual LEDs. U21 turns on
the particular segment or LED pattern, and RN3 and RN4 determine the current through the LEDs, which is
about 25 mA each. The 7 segment display has a common anode configuration for each digit. It should be
noted that the third digit goes to the most significant digit, and they are strobed in order, digit 3, digit 2, digit
1 and LEDs. Note that as there is no pull down resistor, the voltage at the collectors of the drive transistors
will not go to zero when the transistor is off. This can be confusing when troubleshooting with an oscillo-
scope.

The input switches are closed by conductive rubber pads which short an interdigitated pattern on the PCB.
Each has a 10 kohm pull up resistor, and there is a 0.1 microfarad capacitor on each, giving a 1 millisecond
filter when the switch is open. Each switch has its own line--the switches are not strobed, and there is 5V
across each when open, and only a few millivolts when closed.

2.3.6 Power Conversion

There are basically eight functional circuit areas that make up the power control area: ON/OFF CONTROL
and AC FILTER NETWORK, AC LINE AUTORANGE CONTROL CIRCUIT, HV AC-DC RECTIFIER and
CAPACITOR FILTER BANK, MAIN DC-DC POWER CONVERTER CIRCUITRY, MAIN 100KHZ PWM
(Pulse-Width-Modulation) CONTROL NETWORK, ERROR AMPLIFIER & CONTROL CIRCUITRY and the
POWER GOOD DETECTOR network.
2.3.6.1 On/Off Power Control and AC Filter Network
AC power is applied to the PowerPac Basic™ via a power entry module mounted on the chassis of the
unit. This module also contains two user-replaceable 2.5A fuses, one per AC entry point (line and neutral).
Power ON/OFF control is provided by a manual SPST toggle switch S1 mounted on the side of the Pow-
erPac Basic™ chassis.

Caution: Always remove the external AC power plug connector when servicing the PowerPac Basic™, as
BOTH sides of the internal AC connections are NOT opened by the power switch S1. Accidental reversal of
the external phase and neutral AC connections could result in electrical shock of service personnel!

Filtering of common-mode and differential noise levels generated by the high-frequency switching opera-
tions of the PowerPac Basic™ power converter are provided by circuit elements L1, L2, L3, C51, C52,
C53 and C54. 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 element RT1 when S1 is
placed in an ON position. Resistor R43 provides a safe path for discharge of the energies of the filter ele-
ments when the AC power is removed.
2.3.6.2 HV AC-DC Rectifier and Capacitor Filter Bank
The AC output of the PowerPac Basic™ EMI filter network is rectified by the main diode bridge element
D20 to produce a high-voltage DC potential of across capacitor bank C1, C2, C3 and C4. Resistors R2
and R3 provide discharge paths for the capacitor bank when AC power is removed from the unit, as well
as equalization resistances for the bank such that the DC voltage across C2 and C5 match that across C1
and C4.

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System Overview

When the incoming AC voltage is nominally 120VAC, D20 and the capacitor bank is configured automati-
cally to be a "voltage-doubler" network. When the incoming AC line is nominally 240VAC, the configura-
tion of D20 and the capacitor bank is changed to be a full-wave rectifier design. The configuration change
is performed by Triac D3 in the AC LINE AUTORANGE CONTROL subsystem.

Diode LED8 provides visual indication to the user that high-voltage potentials exist across the filter capac-
itor bank when the PowerPac Basic™ is turned ON by power switch S1.
2.3.6.3 AC Line Auto Range Control
The PowerPac Basic is designed to be operated from either 120VAC or 240VAC power without requiring
the user to manually reconfigure the HV rectifier and capacitor bank circuitry to do so. The reconfiguration
is performed electronically by the circuits in this particular subsystem.
Diode D1 and capacitor C20 form a simple half-wave rectifier to generate a DC voltage across C20 that is
directly proportional to the peak magnitude of the AC voltage at the output of the PowerPac Basic EMI fil-
ter network (see section 1.5.1). A sample of this voltage magnitude is then produced by a resistive divider
network formed by R6, R7 and R5. If this voltage sample is greater than the zener voltage of Z1, then
transistor Q1 is turned ON completely, reducing the gate-to-source potential of Q2 to less than one volt
such that this MOSFET is turned OFF. With Q2 off, the gate current for Triac D3 is removed, thus turning
this part OFF. With D3 in an OFF state, the connection path from the center connection of the main filter
capacitor bank is then removed. The bridge diode D20 and the capacitor bank then acts as a full-wave
rectifier and filter network. The values of the resistances in the sampling network have been selected such
that zener Z1 will conduct when the AC voltage from the EMI filter has a nominal RMS value of 145V or
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 Z1 (120VAC operation), then MOS-
FET Q2 is allowed to be turned ON via bias resistors R8 and R9 tied to filter capacitor C20. Transistor Q1
is then placed in an active state (not fully ON) by the voltage developed across resistor R1 by the current
in Q2. In this case, Q1 and Q2 are turned ON to a point where the gate-to-source potential for Q2 is suffi-
cient to develop approximately 1V across resistor R1, for a drain current level of about 1/100 or 0.01
amperes. Diode D2 conducts in this state with an approximate voltage drop of 0.5 volt. Capacitor C36 pro-
vides for filtering of the gate voltage of Q2. Capacitor C67 and resistor R4 also are used for noise filtering
of the base-to-emitter junction voltage of Q1.
This current value is sufficient to turn Triac D3 fully ON. With D3 ON, D20 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.
LED9 provides a visual indication to the user that the autorange control circuit is operational when the
incoming AC power is within the 120VAC ranges. This LED will extinguish when 240VAC power is present
since Q2 will be in an OFF state under this power line condition. Resistor R11 is used to "trim" the bright-
ness of the LED to a proper visual level. Resistor R61 is a low-impedance bias resistor for the gate-to-
MT1 terminals of D3.
2.3.6.4 Main DC to DC Power Converter Circuitry
The heart of the PowerPac Basic is the main DC-to-DC switch-mode power converter subsystem. The
configuration of the converter circuit used is that of a "flyback" converter topology. The power paths of the
topology are formed by Q6, T1, D18 and an output filter capacitor bank formed by C9 and C11. The term
"flyback" has been applied to this topology to depict the "energy store & then release" operational charac-
ter of the circuit
The mode of energy storage of the topology is discontinuous over any switching period. Here, energy is
first stored in the magnetic field of T1 whenever Q6 is ON, and subsequently used completely for output

2-4 100-2474A 09/02

 System Overview

load power when Q6 is turned OFF. The switching period is nominally 10 microseconds, for a switching
frequency of 100 kHz. The phasing of the windings of T1 are such that diode D18 is reverse-biased when-
ever Q6 is ON, and is forward-based whenever energy is being delivered to the PowerPac Basic load via
the secondary winding of T1. During the ON time of Q6 in a switching period, load power is maintained by
the energy stored in the output capacitor bank C9, C11 whenever D18 is not conducting. Operational
waveforms at important points in the power stage are shown (ideal form factors). Under typical operational
conditions of load values, the basic power transfer characteristic of the PowerPac Basic can simply be
expressed in equation form as:
P(out) = V(out) X I (out)
P(out) = output power in watts, V (out) and I (out) as output DC voltage and current magnitudes respec-
tively, L (prim) = open-circuit primary inductance of T1 (pin 1 to 13) in henries, IP = peak drain current
value in amperes at the time Q6 is turned OFF, V1 as the DC voltage at pin 1 of T1 relative to PGND in
volts, ton as the total ON time of Q1 during a switching period in seconds, and fS as the switching fre-
quency of the power converter in Hz.
In the case of the PowerPac Basic™ converter system, the switching frequency is maintained at a con-
stant value of 100,000 Hz. From the above relationships, it can be seen that the ON time of Q6 can be
then be increased or decreased to accommodate changes in both output power needs. The adjustment of
the ON time or Q6 is performed by the pulse width modulation (PWM) control system of the power system
of the PowerPac Basic™.
On the output side of the converter network, inductor L5 and capacitor C10 are high frequency filters to
reduce switching noise on the output lines of the converter. A sample of the output voltage value for the
control system of the PowerPac Basic™ is obtained via the resistive divider network formed by R25 and
R31.
A sample of the current in Q6 is also needed for the control system of the power stage. This sample is
obtained indirectly by simply monitoring the voltage across resistors R36 and R69 in series with the
source lead of Q6.
The drive signal from the control system for Q6 is obtained from the interface circuitry formed by R64,
R15, R16, R17, C28 and Q4. Transistor Q4 is used to enhance the turnoff character of the drive signal for
the gate of Q6, while C28 serves to control the risetime of the drive voltage waveform.
Two sets of snubber networks are used in the converter to protect Q6 from high voltage spikes caused by
leakage inductance effects in T1 at the instant Q6 is turned OFF during a switching period. Diode D15,
resistors R70, R71 and capacitor C57 form a voltage-clamp-style snubber network for collecting the leak-
age energy of T1 in a safe manner. The other snubber network formed by diode D19, R65 and C3 is used
to reduce and dampen the high-frequency oscillations at the drain of Q6 that occur whenever the energies
in T1 have been depleted during a switching period.
2.3.6.5 Main PWM Control Network
To provide control of the ON time of Q6 in the power stage of the PowerPac Basic™, a fixed-frequency
pulse-width-modulation (PWM) network is used. The heart of this network is U1 which contains all essen-
tial parts of the PWM including the 100 kHz clock generator. The PWM converts an analog combination of
error signals from the voltage feedback network (see section 1.5.6) and the voltage analog of the current
in Q6 to a time-varying drive signal for the power stage of the PowerPac Basic. 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.
The values for resistor R14 and capacitor C7 have been selected to set the PWM oscillator/clock fre-
quency in U1 at a constant value of nominally 100kHz. At the start of a switching period, the output pin of
U1 produces 10V to start a drive pulse for the main converter stage. When the level of the current sample
voltage across resistor R22 matches the error voltage level at pin 1, the drive pulse from U1 is terminated.
The error voltage at U1 pin 1 is generated by the error amplifier & control circuitry via a linear opto-isolator

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System Overview

device U2, resistor R24 and buffer amplifier U3A. U2 also provides safety isolation of the output GND of
the system from its PWR GND side.
The current sample mentioned above is supplemented by an additional voltage "ramp" generated by
resistor R18, capacitor C14 and transistor Q3, using the drive voltage from U1 whenever it is active.
Resistor R13 and transistor Q15 (connected as a diode) clamp the input potential to the ramp-generating
circuit to no more than 5.6V during the drive pulse interval. Transistor Q14, resistors R21 and R34 form a
buffer amplifier network between the base of Q3 and the "clock ramp" pin of U1. Therefore, whenever the
output pin of U1 is in a high state (drive time), a fixed "ramp" of voltage is added to the main converter cur-
rent sample. This supplemental ramp is needed to permit the PWM control network to operate properly
whenever the output load of the PowerPac Basic™ is very small. Transistors Q13 and Q15 connected as
shown provide temperature compensation elements for the base-emitter junctions of Q14 and Q3,
respectively, so that the supplemental ramp voltage remains constant as the ambient temperature
changes.
U1 also contains a voltage regulator circuit which provides a fixed 5V potential for its internal circuits as
well as for the ramp generation network noted above. The power for this regulator comes from the
+12V(P) output of the auxiliary power converter network. Capacitors C21 and C22 are filter components
for the +12V(P) line at U1's location, while capacitor C37 is a decoupling element for the 5V output of U1.
Resistor R73 is a "dummy" load for the 5V output of U1 to insure that the internal regulator of this inte-
grated circuit (IC) is biased correctly under all PWM operating conditions.
To provide additional filtering of the switching noise at the current-sense pin of U1, a "blanking" network
has been included in the PWM design. This network is composed of transistor Q5, resistors R19 & R62
and capacitor C8. This capacitor is used to AC-couple the drive signal into the blanking circuit such that
Q5 is turned ON only for approximately 150 nanoseconds whenever a drive pulse from U1 occurs. With
Q5 in an ON state, the current-sense pin of U1 will be disabled for the Q5 ON time period. This simple net-
work then prevents any high frequency noise occurring at the instant of the start of drive pulse from upset-
ting the control system in U1.
To prevent transient excursions of the drive waveform during turn-on and turn-off intervals from damaging
U1, two diode "clamps" have been provided on its output pin. Schokkty diode types of the power variety
are used here to insure the clamp voltage drop is small, with one diode tied to the +12V(P) point on U1
and the other tied to the ground potential of this IC (PGND).
2.3.6.6 Error Amplifier & Control Network
The sample of the output voltage provided by R25 and R31 in the main DC-DC converter subsystem is
used by the PowerPac Basic™ controls to monitor the potential level of the PowerPac Basic™ output.
This sample, along with a sample of the output current magnitude via resistors R12, R66 and R52, is com-
pared with a precision reference voltage set by the PowerPac Basic™ central controls and then used to
produce an error signal for the PWM control network. This error signal then causes the system to make
adjustment in the ON time of the power switch in the main converter area so that the output voltage and/or
current level remains constant with changes in AC power and/or load resistance.
A buffer amplifier and filter network formed by U18B, R56, R63, C46 and C59 are used to apply the output
current sample to the reference control area of the PowerPac Basic™. For the output voltage sample,
U18A, R54, R55 and C45 form a similar buffer for this signal. U12A provides the proper signals to the
PowerPac Basic 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 PowerPac Basic™, based on the
user settings for output voltage and current levels. U14 provides a highly regulated 2.5V bias voltage for
the operations of U12A and U13A, using the +5V bias voltage from the auxiliary power converter of the
PowerPac Basic™. To provide short-term over-voltage protection for the buffer areas related to the output
current sample, a power zener diode D4 has been added across R66, R12 and R52 for this purpose.
Capacitor C64 is a high frequency noise reduction element for the output of U18B.
The set-point voltage produced by U13A varies from 0 to 2.20 volts in magnitude, depending on the set-
ting for desired value of output voltage or current. This voltage is then compared against the sampled

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 System Overview

value of the actual output potential of the PowerPac Basic™, using a simple inverting amplifier system.
This system is formed by U5B, R29, R30, R32, R33 and capacitors C13, C19 and C38.
Resistors R30 and R32 provide a slight negative voltage bias on the non-inverting terminal of U5B 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 sub-
system will not cause the unit to produce full power when the shutdown command is removed. The nega-
tive bias source is the -1.2V potential generated in the auxiliary converter subsystem. Capacitor C13 is a
high frequency noise reduction element for pin 5 of U5B. To provide for input offset compensation, the
value of R29 has been selected to be the same as R30. Resistor R33, along with capacitors C19 and
C38, are the feedback elements of the error amplifier. Their values, as well those selected for R30 and
R29, have been carefully chosen to provide adequate margin in overall control stability for the PowerPac
Basic™ power conversion system under all specified load conditions.
U5A, along with R28 and R27, provide a buffer driver for the linear opto-isolator device U2 to permit the
error amplifier voltage at U5A pin 1 to be translated to the power ground side of the PP300 converter sys-
tem (see section 1.5.5). Capacitor C18 serves as a high-frequency feedback compensation element for
the U5A-to-U2 drive network circuit. The values of R27 and R24 set the DC gain of the opto-isolator net-
work at a value of R24/R27, or approximately 0.8. The value of R28 has been chosen to provide proper
bias current for the main diode in the opto-isolator. Figure 1.3 shows the internal details of U2 and the
amplifier circuitry surrounding it.
As shown in this illustration, there are three opto-diodes in U2, two of which are drive elements for the
third diode for the output signal. The circuit in Figure 1.3 allows for compensation for changes or differ-
ences in the current gains of the driver diodes, such that the end-to-end gain of the network is linear and
constant over a wide frequency range.
The entire power converter operation can be terminated by the application of a positive SHUTDOWN
command issued by the PP300 output control system. To translate this command to the primary ground
side of the converter system, an opto-coupler is used (U4). Resistor R10 limits the current drawn from the
SHUTDOWN control signal for driving the opto-diode in U4. The opto-transistor in U4, when the SHUT-
DOWN command is present, then disables the operation of the PWM IC U1 via resistor R20 when this
transistor is activated. U4 uses the +5V bias from the PWM IC U1 as a source of drive power disabling the
PWM operations.
2.3.6.7 Auxililary DC-DC Converter Network
A second power converter network is included in the PowerPac Basic™ power system to provide voltages
for the various analog and digital control circuits, as well as potentials for the PWM control and drive cir-
cuits. This network is called the "housekeeping" power converter for this reason, as it operates indepen-
dently of the main DC-DC power converter stage.
This converter subsystem produces four DC voltages (+12V(FAN),+12V(S), +5V(S), and -1.2V for the
PowerPac Basic™ electronics and one more DC output for powering the main PWM control network
(+12V(P)). In the latter case, this output is referenced to the PWR GND side of the converter, while the
former voltages are all referenced to the output GND potential. The +12V(FAN) is used solely for power-
ing the PowerPac Basic™ fan assembly whenever the auxiliary converter is ON.
The power source for this special converter is generated from the user's AC line, using the AC potential
from the output of the EMI filter network (see section 1.5.1). This provides a rapid turnoff of the PowerPac
Basic™ display and fan when the unit's AC power is removed, even though the energies stored in the
main capacitor bank (C4 and C5, drawing zones A4, B4) have not been fully discharged. A small diode
bridge element D5 is used to rectify the AC potential and capacitor C17 is used to filter the rectified AC to
produce a high-voltage potential for operating the housekeeping DC-DC converter. Resistor R68 insures
that no high-currents from the main power converter bridge element (D20) will appear in the lower diode
elements of D5. Like the main DC-DC converter topology, the auxiliary power converter circuit is a discon-
tinuous "flyback" design, with T2 serving as the magnetic storage element. However, unlike the main DC-
DC power converter, it is a fixed-frequency design that operates primarily in a current-limit mode when-

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System Overview

ever it is active (often called a "burst-mode" converter). The heart of the converter is its control IC U6,
which contains all of the central clock & 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-jittering features for lowering EMI emissions. The nominal operational
frequency of the housekeeping converter is 130 kHz. Typical U6 operational waveforms in the auxiliary
power converter circuit.
The auxiliary converter can be configured to use two different IC types for U6. Resistors R37, R38 and
R72 provide a bias for U6 via diode D21 such that the rectified AC line voltage value across C17 must be
at least 100 VDC before U6 is allowed to operate to permit the housekeeping converter to be operational.
Capacitor C23 is a high-frequency filter capacitor for the 5.8V reference voltage produced by U6.
ON-time duty cycle control of the power switch in U6 is accomplished by voltage control of the potential at
the EN/UV pin of U6. This function is provided by opto-coupler U7 which provides isolation of the power
ground of the auxiliary converter from the output ground of the PowerPac Basic™. The level of conduction
of the transistor in U7 is controlled by a small feedback and control network on the output ground side of
the converter. This network is composed of resistors R41, R42, R47, capacitor C31 and IC D10. Drive
power for the opto-diode in U7 is provided via resistor R40 tied to the +12V(S) output voltage line of the
auxiliary converter.
D10 contains both a 2.5V reference voltage element and a operational amplifier. A sample of the +12V(S)
output is provided via the resistive divider network formed by R41 and R42. This sample is then compared
internally in D10 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 U7 is tied to this point, changes in the error voltage from U6
will cause this diode to conduct more or less and in a direction so as to adjust the ON time of U6 to main-
tain the +12V(S) output constant with changes in loading and the DC input voltage from C17.
Diode D9 and capacitors C24 & C27 are the output elements of the converter for the +12V(S) and
+12V(FAN) potentials. A small low-pass filter network (inductor L4 and capacitors C26 & C29) is used to
produce the +12V(S) output from the fan power point and helps to reduce high-frequency voltage ripple
caused by the fan operation. Capacitor C31 serves as the single feedback compensation element for the
+12V regulator network for stability of control. Capacitor C56 provides an AC connection for the power
and output grounds for lowering EMI emission levels.
A linear voltage regulator IC (U8) is used to generate the +5V(S) potential from the +12V(S) output.
Capacitors C32 and C33 are the output filters for the +5V(S) line.
To generate the nominal -1.2V(S) potential for the biasing the error amplifier in the PWM control area, a
simple half-wave rectifier and capacitor filter arrangement is employed, using the a small amount of power
from the +12V(S) secondary winding of T2, the "transformer" of the auxiliary converter. Diode D13, resis-
tor R48 and capacitors C34 and C42 are the elements of the -1.2V output, with diodes D11 and D12 con-
nected in series to form a 1.4V voltage " clamp" on this output point.
Another secondary winding on T2 is used for generating the +12V(P) potential, since its ground return is
referenced to PWR GND rather than output GND. Diode D8 and capacitor C30 are the rectification and fil-
ter elements associated with the +12V(P) output. Regulation of this potential is indirect in nature in that
this potential will "track" that of the regulated+12V(S) output since both secondary windings on T2 are
magnetically coupled. The +12V(P) is used only for powering elements of the main PWM control network.
Special Note: The two+12V output voltages of the PowerPac Basic™ auxiliary supply, as well as the -
1.2V(S) bias potential, can vary significantly in values without affecting the accuracy or operations of the
unit. Critical reference potentials used in the controls of the PowerPac Basic™ are derived using preci-
sion regulator elements that are powered from these voltages.
Two snubber circuits are provided on the primary side of T2 for safe retrieval of the leakage energy when
U6 is turned OFF. One of these networks is a voltage "clamp" design (diode D7, capacitor C15 and resis-

2-8 100-2474A 09/02

 System Overview

tor R35) to keep the maximum drain voltage level (pin 5 on U6) within rating value. The second network is
a simple RC noise suppression snubber (resistor R39 and capacitor C16) placed at pin 5 of U6.
The remaining circuit elements around U6 are used for configuration of the auxiliary converter to use
either a TNY256G or a NCP1054P136 IC for U6. These elements are resistors R100, R101, R102, R103,
diode D100 and capacitor 101 in the PowerPac Basic™ schematic.
2.3.6.8 Power Good Detector
To provide an electrical indication that the auxiliary DC-DC converter network is operating properly, a sim-
ple voltage detector circuit is used. This detector is formed by the circuit elements around comparator
U9B. A separate 2.5V reference voltage has been provided for this area (D14), which is powered from the
+12V(S) line via resistor R45. Capacitor C35 is a filter element for this reference voltage noted as REF2 in
the E8683 schematic, and this point is used in the PowerPac Basic™ output control area.
The magnitude of the +12V(S) is used for generating the POWER_LOW signal from this detector circuit. A
sample of its potential is used for this purpose via the resistive divider network formed by R44 and R49.
When the +12V(S) value reaches approximately 10.8 volts when the auxiliary power converter is turned
ON, the output of U9B (the POWER_LOW output) will change from approximately 5V to 0.1V in value,
indicating that the auxiliary power converter outputs are sufficient to allow the PowerPac Basic™ output
controls to function properly.
Resistors R46, R50 and R51 are used to establish the trip points for comparator U9B, using the reference
voltage of D14. Resistor R46 also provides a pull-up bias for the output of U9B when the detector circuit is
indicating that the 12V(S) has fallen out of tolerance (i.e., less than 10V in value). The POWER_LOW sig-
nal is used by the PowerPac Basic™ logic as an early indication that the AC power for the PowerPac
Basic™ power conversion system has fallen out of tolerance or has been removed.

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 Installation

Section 3
Installation

3.1 Overview
This section of the manual guides you through the installation and setup of the PowerPac Basic™. Successful
completion of the installation in the Installation section represents a preliminary system checkout of the instru-
ment. An installation check sheet is provided in Appendix 11.2.

3.2 Product Catalog Numbers

Note: The PowerPac Basic™ can be purchased under the following catalog items.

164-5050 PowerPac Basic™ Power Supply, 100-120/220-240 V

3.3 Unpacking the PowerPac Basic™

1. Remove all packing material and connect components on a flat, dry surface near an appropriate electrical outlet.
2. Upon receiving your instrument, please check that all items listed were shipped. If any items are missing or dam-
aged, contact your local Bio-Rad office.

3.4 Setting Up the PowerPac Basic™

Note: Be sure to turn off the PowerPac Basic™ unit 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 6 cm clearance around
the power supply. Do not block the fan vents at the rear of the unit.

1. Attach the power cord to the three-pronged receptacle on the back of the PowerPac Basic™. Plug the unit into an
appropriate electrical outlet or power strip.
2. To turn on the PowerPac Basic™ by turning on the power switch.
3. Verify that the fan turns and the keypad display illuminates.

3.5 Connecting the PowerPac Basic™ to the Electrophoresis Cell

Note: .5X TBE buffer can be made from a 10X stock of Bio-Rad premixed buffer solution (161-0741). To
obtain 1 liter of .5X TBE buffer, mix 50 ml of 161-0741 stock solution with .95 liter of Di water to produce a
general buffer solution.

1. Connect the correct polarity of the power cables from the electrophoresis cell to the output jack pair.

Note: The power cable male ends must be fully inserted and seated into the angled output jacks. Recheck for
proper contact seating before proceeding.

100-2474A 09/02 3-1

Installation

2. The buffer tank of the electrophoresis cell can be filled with a buffer such as .5X TBE to allow the PowerPac unit to
run. See Figure 3-1.
3. Set to constant voltage at 190 volts and run the instrument.
4. Observe that there is buffer output activity on the electrode wires and there is some bubbling along the anode and
cathode wires.
5. Check that the power supply current reading is about 360 to 375 mA using .5X TBE buffer.

PowerPac

_
+
+ _
Buffer

Electrophoresis Cell

Figure 3-1: PowerPac to Electrophoresis Setup

6. Set to constant current at 350 mA and run the instrument.
7. Observe that there is buffer output activity on the electrode wires and there is some bubbling along the anode and
cathode wires.
8. Check that the power supply voltage reading is about 175 to 180 volts using .5X TBE buffer.

Note: If the instrument fails to meet the specified voltage and current readings from Section 3.5, check and
troubleshoot the buffer solution, distilled water, electrophoresis cell, cell connections, and cell power cables,
then repeat the tests in Section 3.5.

3.6 Protective Sheet Removal

1. Remove the protective sheet from the top cover.

Note: Residue may appear on the top cover from the adhesive of the protective sheet. Clean the top cover
using a soft cloth and alcohol if residue is evident.

3-2 100-2474A 09/02

 System Checkout

Section 4
System Checkout

4.1 Introduction
This section provides instructions for testing the PowerPac Basic™. The purpose is to verify performance,
functional integrity and to detect faulty operation of the PowerPac Basic™. The system checkout procedure
should be performed following installation or any repair or maintenance of the PowerPac Basic™. The System
Checkout Procedure assumes that the PowerPac Basic™ has been properly installed. Successful completion
of the tests in the System Checkout section represents proper instrument performance. A test certification
sheet is provided in Appendix 11.1.

4.2 Tools and Materials

• Clarostat Model 240C Power Resistor Decade Box (+/- 5% tolerance, purchased at www.clarostat.com)
• 2 Each Fluke True RMS Multimeter Model 189 or equivalent ( 0.1% DC V and 0.15% DC mA Accuracy)
• Banana Plug Adaptor 920-7369
• High Voltage Test Cable Set 800-0838

4.3 Checkout Procedures

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

4.3.1 Power on Test

This section checks the power on condition and firmware.
1. Turn on the PowerPac power and verify the power light illuminates and the display turns on.
2. Verify for fan movement by placing a tissue at the rear panel and checking the tissue is sucked into the fan vent.
3. Verify that no error messages are displayed on the LED display. See Figure 4-1.
4. Verify that the firmware displayed is current at 1.30 or above by holding down on the V/A key switch and power-
ing on the unit simultaneously, then releasing the V/A key switch. The firmware version will be displayed follow-
ing an 888 reading and the run mode switch is not engaged.

Figure 4-1: Front Panel

100-2474A 09/02 4-1

System Checkout

Figure 4-2: Keypad Description

4.3.2 No Load Test

This section checks for no load detection.
1. Set the constant voltage to 100 volts.
2. Press the Start key to run the unit. See Figure 4-2 for keypad descriptions.
3. Verify that the display reads an E1 in approximately 3 seconds to indicate a no load error.
4. Cycle the power to reset the error message.

4.3.3 Overload Short Circuit Test

This section checks short circuit detection.
1. Connect the cable adaptor into any pair of output jacks.
2. Connect one end of the test cable to the positive (red) jack of the cable adaptor and the other end of the test cable
to the negative (black) jack of the cable adaptor.
3. Set the constant voltage to 100 volts.
4. Press the Start key to run the unit.
5. Verify that the display reads an E2 in approximately 3 seconds to indicate an overload error.
6. Turn off the power.
7. Disconnect the test cable and the banana plug adapter from the PowerPac output jacks.
8. Turn on the power.

4.3.4 Sudden Load Change Test

This section checks rapid and variable resistance change detection.
1. Connect the Clarostat decade resistor box to the cable adaptor jacks using the set of test cables.
2. Set the resistance of the Clarostat decade resistor box to 50K ohm.
3. Set the unit to run at 300V constant voltage.
4. Press the Start key to run the unit.
5. Wait approximately 5 seconds for the 25 volts to stabilize, then switch the resistance of the Clarostat decade resis-
tor box from 50 K to 10K ohm.
6. Verify that the display reads an E9 in approximately 3 seconds to indicate a sudden change in load error.
7. Cycle the power.

4-2 100-2474A 09/02

 System Checkout

4.3.5 Auto Power-Up Test

This section checks power AC line restart detection.
1. With the Clarostat decade resistor box connected to the cable adaptor jacks, set the resistance to 5K ohm.
2. Set the unit to run at 100V constant voltage.
3. Press the Start key to run the unit.
4. Wait approximately 10 seconds for the 100 volts to stabilize, then unplug the line cord from the power entry mod-
ule and wait 5 seconds then reconnect the AC line cord into the power entry module.

Caution: All safety precautions must be observed while performing step 4.

5. Verify that the display reads an E7 to indicate a sudden loss in power.

6. After the E7 is displayed, cycle the power.
7. Verify that the unit runs automatically from its previous setting and displays 100V.
8. Press the Stop key.

4.3.6 Clarostat Model 240C Decade Box Checkout

Note: This section provides test procedures to check functionally of the load box prior to testing the
PowerPac Basic performance to specifications.

1. Connect the set of test cables to the left or right side pair of jacks of the Clarostat decade resistor box.
2. Connect the other end of the test cables to the digital ohm meter.
3. Set the resistance box to 50 ohm.
4. Verify the ohm meter reads between 47.5 ohms to 52.5 ohms. Specification is 50 ohm +/- 5%.
5. Set the resistance box to 1.2K ohm.
6. Verify the ohm meter reads between 1.140 K ohms to 1.260 K ohms. Specification is 2.5 K ohm +/- 5%.
7. Set the resistance box to 2K ohm.
8. Verify the ohm meter reads between 1.9 K ohms to 2.1 K ohms. Specification is 2 K ohm +/- 5%.
9. Set the resistance box to 500 ohm.
10. Verify the ohm meter reads between 475 ohms to 525 ohms. Specification is 400 ohm +/- 5%.
11. If the Clarostat decade resistor box meets all specifications, proceed to the following section. If the Clarostat
decade resistor box does not meet specifications, the resistor box should be examined and repaired before proceed-
ing to the following section.

4.3.7 Voltage and Current Specification Table

Display and Output Technical Specification Table
Specification Voltage Current
Accuracy 20-100V, +/-3V 5-100 mA, +/-3 mA
100-300V, +/-2% 100-400mA, +/-2%
Display Readout Stability +/-2% +/-2%

100-2474A 09/02 4-3

System Checkout

Voltmeter Current
Meter
VDC mA
Clarostat
Decade Box
PowerPac Basic™

+ - - - + _ + -
+ +

Figure 4-3: Meter Setup

4.3.8 Voltage and Current Output Measurement Setup

Note: There is a +/- 5% tolerance when using the Clarostat Model 240C Decade Power Resistor box.

1. Disconnect the test cables from the Clarostat decade resistor box and the cable adaptor jacks.
2. Set the Clarostat decade resistor box to the resistance to 1200 ohm.
3. Connect the PowerPac Basic™, Clarostat decade resistor box, both multimeters, and test cables as shown in Figure
4-3.

4.3.9 100V Constant Voltage Test

This section checks both the mid range voltage and current.
1. Set the unit to run at 100V constant voltage.
2. Verify the resistance of the Clarostat decade resistor box is set to 1200 ohm.
3. Verify the test setup is followed as described in Section 4-3.
4. Press the Start key to run the unit.
5. Verify the output on the voltmeter reads between 98.5 volts to 101.5 volts.
6. Verify the output on the current meter reads between 81.6 mA to 85 mA.
7. Verify the PowerPac Basic™ voltage displays 100 volts.
8. Verify the PowerPac Basic™ current displays between 82 mA to 84 mA.

4-4 100-2474A 09/02

 System Checkout

9. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac Basic™ run, do not exceed 2 hours of each run.

4.3.10 20V Constant Voltage Test

This section checks the low voltage.
1. Set the unit to run at 20V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 1200 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 18.5 volts to 21.5 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 2 mA.
6. Verify the output range of the current meter reads 16.7 mA +/- 5%.
7. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac Basic™ run, do not exceed 2 hours of each run.

4.3.11 150V Constant Voltage Test

This section checks the mid range voltage.
1. Set the unit to run at 150V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 1200 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 147.75 volts to 152.25 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 2 mA.
6. Verify the output range of the current meter reads 125 mA +/- 5%.
7. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 15 minutes of each run.

4.3.12 280V Constant Voltage Test

This section checks the high range voltage.
1. Set the unit to run at 280V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 1200 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 275.8 volts to 284.2 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 2 mA.

100-2474A 09/02 4-5

System Checkout

6. Verify the output range of the current meter reads 233.3 mA +/- 5%.
7. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 5 minutes of each run.

4.3.13 20V Constant Voltage Test

This section checks the low voltage.
1. Set the unit to run at 20V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 500 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 18.5 volts to 21.5 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 2 mA.
6. Verify the output range of the current meter reads 40 mA +/- 5%.
7. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 30 minutes of each run.

4.3.14 150V Constant Voltage Test

This section checks the mid range voltage.
1. Set the unit to run at 150V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 500 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 147.75 volts to 152.25 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 2 mA.
6. Verify the output range of the current meter reads 300 mA +/- 5%.
7. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 5 minutes of each run.

4.3.15 170V Constant Voltage Test

This section checks the mid range voltage function with high resistance load.
1. Set the unit to run at 170V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 25K ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 167 volts to 173 volts.

4-6 100-2474A 09/02

 System Checkout

5. Verify the output on the current meter reads between 2 mA to 8 mA.

6. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 2 hours of each run.

4.3.16 290V Constant Voltage Test

This section checks the high range voltage only.
1. Set the unit to run at 290V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 1200 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the voltmeter reads between 286 volts to 294 volts.
5. Press the Stop key.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac run, do not exceed 5 minutes of each run.

4.3.17 380 mA Constant Current Test

This section checks the maximum current.

Caution: To prevent permanent internal damage to the Clarostat decade box from high temperatures
produced during a PowerPac high current run, do not exceed 5 minutes of each run.

1. Set the unit to run at 380 mA constant current.

2. Set the resistance of the Clarostat decade resistor box to 500 ohm.
3. Press the Start key to run the unit.
4. Verify the output on the current meter reads between 376 mA to 384 mA.
5. Verify the output on the voltmeter reads between 180 volts to 200 volts.

Caution: To prevent damage to the current meter from current runaway, set the current range from the 400
mA range to the 10A range and move the meter cable to the 10A (+) jack.

6. Press the Stop key.

4.3.18 300V Burn-In Test

This section checks for drift and stability over a long run. This test is recommended if power conductors are
replaced in the power converter or primary circuits.
1. Set the unit to run at 300V constant voltage.
2. Set the resistance of the Clarostat decade resistor box to 30K ohm.
3. Press the Start key to run the unit.

100-2474A 09/02 4-7

System Checkout

4. Verify the output on the voltmeter reads between 285 volts to 315 volts.
5. Verify the difference of the PowerPac Basic™ display and the output on the voltage meter reads less than 2 volts.
6. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 3 mA.
7. Verify the output range of the current meter reads between 8.5 to 11.5 mA.
8. Allow the unit to run for 2 hours.
9. Verify the output on the voltmeter reads between 285 volts to 315 volts.
10. Verify the difference of the PowerPac Basic™ display and the output on the voltage meter reads less than 2 volts.
11. Verify the difference of the PowerPac Basic™ display and the output on the current meter reads less than 3 mA.
12. Verify the output range of the current meter reads between 8.5 to 11.5 mA.
13. Press the Stop key.
14. Disconnect and remove all test setup from the PowerPac Basic™ instrument.

4-8 100-2474A 09/02

 Preventative Maintenance

Section 5
Preventative Maintenance

5.1 PowerPac Basic™ Preventative Maintenance

The PowerPac Basic™ 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 Basic™ preventative maintenance should be performed as part of the PowerPac Basic™ main-
tenance procedure.

5.1.1 Daily Maintenance

1. Unplug the PowerPac Basic™ unit.
2. Use a damp cloth to wipe down the outer case of the PowerPac Basic. Avoid wetting the power switch, power
entry module, 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 Longterm 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 Maintence procedure before long term storage.
The unit should be stored in a plastic bag for dust particle protection.

5.1.4 PowerPac Basic™ 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.

100-2474A 09/02 5-1

Preventative Maintenance

PowerPac Basic™

Preventative Maintenance Report

Customer: Case Number:

Performed by: Serial #: Date:

Component Checked Replaced Cleaned

Casing
Output Jacks
Firmware version #
Keypad
Display Function
Power-On Test
No Load Test
Overload Short Circuit Test
Sudden Load Change Test
Auto Power-Up Test
100V Constant Voltage Test
20V Constant Voltage Test
150V Constant Voltage Test
280V Constant Voltage Test
170V Constant Voltage Test
290V Constant Voltage Test
380 mA Constant Current Test
300V Burn-In Test

Comments:

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

Performed by____________________________________________ Date__________________________

Bio-Rad Service Engineer

5-2 100-2474A 09/02

 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 parts and assem-
blies. Alignment procedures that should be performed when a part or assembly is replaced are listed in this
section in the Replacement /Adjustment Matrix. The procedures indicated should be performed 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 otherwide specified, following
the removal instructions in reverse order will provide the correct procedure for
replacing the assembly.

6.2 Replacement/Adjustment Matrix

There will not be any calibration procedures performed from any parts assembly or disaasembly. System
Checkout procedures are followed for any component and board replacements or removal.

6.3 Removal and Replacement Procedures

Tools Required
• 3/16” Slotted screwdriver
• Diagonal Cutter

100-2474A 09/02 6-1

Removal and Replacement

6.3.1 Exploded View

This section gives an overall view of the main PowerPac Basic™ assemblies. See Figure 6-1.

920-6946
Top Cover

920-6862
Fan
Keypad

800-8683-01
Power Converter Board

Metal Jack Power Switch

920-6951 900-0524

Figure 6-1: Exploded View

6.3.2 Front Panel/Top Cover

1. Insert a thin, flat blade screwdriver in the slots of the bottom case shown and push in to release the top cover tabs
from the bottom case latches. See Figure 6-2.
2. Lift and remove the front panel/top cover from the bottom casing.
3. Unlock the ribbon cable from J5 connector of the power board. See Figure 6-3.
4. Install the front panel/top cover in the reverse order of the above steps

Figure 6-2: Top Cover Removal Figure 6-3: Ribbon Cable Removal

6.3.3 Top Cover (920-6946)

1. Insert a thin, flat blade screwdriver on the underneath side of the front cover/top cover between the latch and the
catch. See Figure 6-4.
2. Slide the front cover forward to separate from the Top Cover (920-6946).

6-2 100-2474A 09/02

 Removal and Replacement

3. Install the front panel/top cover in the reverse order of the above steps.

Figure 6-4: Front Cover/Top Cover Removal

6.3.4 Display Board Assembly (800-8683-01)

1. Remove the two Phillips screws from the Display Board Assembly (800-8683-01). See Figure 6-5.
2. Push out and remove the keypad from the Display Board Assembly (800-8683-01). See Figures 6-6 and 6-7.
3. Unlock and disconnect the ribbon cable from the board connector. See Figure 6-8.
4. Install the display board in the reverse order of the above steps.

Figure 6-5: Display Board Removal Figure 6-6: Keypad Removal

Figure 6-7: Remove Keypad Figure 6-8: Ribbon Cable Removal

100-2474A 09/02 6-3

Removal and Replacement

6.3.5 Fan (920-6862)

1. Disconnect the fan cable from J1 connector of the power board. See Figure 6-9.
2. Remove the Fan Assembly (920-6862) from the bottom case slots.
3. Remove the fan rubber boot (920-6961) from the fan body.
4. Install the fan assembly in the reverse order of the above steps.

Figure 6-9: Fan Assembly Removal

6.3.6 Power Converter Board (800-8683-01)

1. Remove the Power Converter Board Assembly (800-8683-01) from the bottom case. See Figure 6-10.
2. Install the Power Converter Board (800-8683-01) in the reverse order of the above steps.

Figure 6-10: Power Converter Board Removal

6.3.7 Fuse (900-7283)

1. Insert a flat blade screwdriver on the tabs of the power entry module fuse drawer to release. See Figures 6-11 and
6-12.
2. Remove the 2.5 A, 250 V, 5 X 20 mm fuses (900-7283).

6-4 100-2474A 09/02

 Removal and Replacement

3. Install the fuses in the reverse order of the above steps.

Figure 6-11: Fuse Removal

Figure 6-12: Fuse Location

6.3.8 Dual Insulated Jack (920-6957/ 920-6962)

1. Remove top cover from front cover.

100-2474A 09/02 6-5

Removal and Replacement

2. Grasp the Dual Insulated Jack (920-6957 Red Jack, 920-6962 Black Jack) and slide out from the top cover. See
Figure 6-13.

Figure 6-13: Dual Insulated Jack Removal

3. Install the insulated jack in the reverse order of the above steps.

6.3.9 Dual Metal Jack (920-6951)

1. Unsolder the Dual Metal Jack (920-6951) from the solder side (8 pins) of the Power Converter Board Assem-
bly (800-8683-01). See Figure 6-14.
2. Install the jack in the reverse order of the above steps.

Figure 6-14: Dual Metal Jack Removal

6-6 100-2474A 09/02

 Removal and Replacement

6.3.10 Display PCB from Power PCB Removal (800-8683-01)

1. Cut and remove the PCB of the Display Board Assembly from the Power Converter Board Assembly using a diag-
onal cutter. See Figure 6-15.

Figure 6-15: Display PCB from Power PCB Removal

100-2474A 09/02 6-7

 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
Basic™. Each procedure also has a short introduction explaining its purpose.

Note: The PowerPac Basic requires no alignment, calibration, and adjustments. Refer to the System
Checkout section for testing.

100-2474A 09/02 7-1

 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 Basic™. This section may be expanded to include additional 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 Basic™ Power Supply

This section provides safety information and troubleshooting information listed by problems, possible causes
and solutions.

Caution: The extruded heatsink of the main FET at Q6 of the power converter board is connected to power
ground and is not safe to touch while the unit is plugged in even when the power switch is turned off. The
push-on heatsinks of D3 and Q2 are NOT isolated and should not be touched while the unit is plugged in even
if the power switch is turned off. The capacitors across the DC link C4 and C5 stay charged for more than a
minute after turnoff. LED # 8 is an indicator for the state of charge. If the LED is completely out when viewed
under low light, it is safe to work on the power converter board.

Problem Possible Cause Solution

No display No power to unit Check the power switch to be sure it is on.
No connection at AC input Check the power cord connections.
Bad power switch Check the power at the outlet.
Bad 5V circuit Check power entry module
Bad power board Check fuses
Check LEDs 8 and 9 are lit
Check for proper cable seating from the
display board and power board
Reseat microprocessor
Replace display cable or display board
Replace microprocessor
Check and replace 5V circuit at U8 regu-
lator, C32,C33
Replace power board

Missing display seg- Display connection problem Check for proper cable seating from the
ments Bad display board display to power board
Bad power board Replace display board or LEDs
Replace power board

100-2474B 04/03 8-1

Troubleshooting

Problem Possible Cause Solution

Bad keypad response Display board connection prob- Check for proper cable seating from the
lem display to power board
Bad keypad Check for proper keypad seating
Bad display cable Replace keypad
Replace display board
Replace power board
Unit freezes or locks up Corrupt flash U16 ROM Reseat microprocessor
during power-up Bad microprocessor Replace microprocessor
Bad power board Replace power board
No power at start up, no No connection at AC input Check the power switch to be sure it is on.
lights Bad power switch Check the power cord connections.
Bad 5V circuit Check the power at the outlet.
Bad power board Check power entry module
Check fuses
Check LEDs 8 and 9 are lit
Check for proper cable seating from the
display board and power board
Reseat microprocessor
Replace display cable or display board
Replace microprocessor
Check and replace 5V circuit at U8 regu-
lator, C32,C33
Replace power board
No or low fan move- Loose or unseated fan connector Check for proper fan cable seating
ment Bad fan assembly Replace fan assembly
Bad 12V circuit Check 12V fan input and replace
D9,C24,C27,C26,C29,C31,C31
No display but fan is Microprocessor is not operating Check for proper socket seating of micro-
running processor
Check at TP8 that power is good and in
high state
Replace microprocessor
Replace power board
Internal power board Bad components on power board Check and replace Q6 FET
LED # 8 turns off in a Check and replace leaky C4,C5
few seconds after out- Check and replace D20 bridge rectifier
put run is stopped Replace power board

Fuse blows repeatedly D18 output diode and main Q6 Check and replace
FET damaged and shorted and D18,Q6,R16,Q4,R15,R64,U1
other adjacent compoents Replace power board

Unable to run and out- D4 diode is bad or reversed Check or replace D4 diode
put above 147 volts Replace power board

8-2 100-2474B 04/03

 Troubleshooting

Problem Possible Cause Solution

E1 error No load indication Check for bad cell cable plugs and plati-
num wire continuity
Check and replace D18 diode due to junc-
tion temperature overheating above 90C
Check and replace current sensing resistor
bank R66,R12,R52 ( Series =4.886 ohms)
Replace power board
Low output current Damaged output protection Check and replace D18 output diode
zener diode Check and replace current sensing resistor
Damaged current sense resistors bank R66,R12,R52 ( Series =4.886 ohms)
from shorting output while run- Replace power board
ning at high voltage
High current output out Damaged output protection Check and replace D18 output diode
of specification zener diode Check and replace current sensing resistor
Damaged current sense resistors bank R66,R12,R52 ( Series =4.886 ohms)
from shorting output while run- Replace power board
ning at high voltage
E14 error Voltage is out of range Check and replace U18 op amp
Replace power converter board
E09 error v1.31 firmware at U11 may be Check firmware version and upgrade to
sensitive at lower current range v1.32 per ISA # 002A
on some electrically noisy units
E10 error Likely to be a failed keypad or Check keypad connection and reseat
poor connection of the keypad to Replace keypad
the PCB inside

8.3 Error Codes

This section describes the error code alert messages and descriptions and recommended customer action.

Error Code Description Customer Solution

E1 No load detected Verify all electrical connections
Instrument not connected to Verify buffer levels where appropriate
power supply Check buffer conductivity for high resis-
The current load is below 2 mA tivity
E2 Short circuit Check for and correct any short circuit or
The current load exceeded 400 excessive load problem.
mA Then,press Start key to resume the run or,
to clear the error code, press any key
other than the Start or Stop key.

E3 Overvoltage Check all electrical connections to the

Voltage >330 V electrophoresis cell and whether the cell
contains the appropriate volume.
Then,press Start key to resume the run or,
to clear the error code, press any key
other than the Start or Stop key.

100-2474B 04/03 8-3

Troubleshooting

Error Code Description Customer Solution

E5 A power failure occurred during To clear the error code, press any key
a timed run with Power Fail other than the Start or Stop key.
Detection (PFd) activated, but
run is completed. Power Fail
detection (PFd) is disabled after
completion or termination of
each run.
E6 A power failure occurred during To clear the error code, press any key
a timed run without Power Fail other than the Start or Stop key.
Detection (Pfd) activated and
run is not completed.
E7 Power failure occurred during To clear the error code, press any key
untimed run and run is not com- other than the Start or Stop key.
pleted. Power fail detect (PFd)
cannot be activated for untimed
runs.
E8 Regulation error Internal power board problem associated
Power supply was trying to with the high voltage circuits.
increase or decrease voltage and
the unit is not responding to the
change.
E9 Change in load resistance. The Check and correct any buffer resistance or
PowerPac Basic detects drastic cell cable/wire problem then,
changes in resistance of the cell: *Press Start key to resume run or
the greater of 20% change or 15 *Press any key, other than the start key to
mA when above 16 mA clear E9 code

Certain applications exhibit fluc- The change in resistance feature can be

tuations in resistance that can deactivated to allow uninterrupted com-
trigger the change in resistance pletion of a run by:
error codes. *Make sure the parameter key is in cur-
rent mode(current LED is lit)
*Hold down down the stop key for 2 sec-
onds until the display reads dE9.
E10 Unacceptable value(s) entered Clear the code by pressing any key other
than the start key, then enter values
Temperture sensor sensing over- within the range of PowerPac Basic and
temperature in power board press start.

Key is sticking or jammed Check fan is seated properly by the top

and bottom casing.

Check fan is working properly

Check for properly keypad seating and

key connection to the display board

Replace keypad/display board

8-4 100-2474B 04/03

 Troubleshooting

Error Code Description Customer Solution

E14 Internal Over Voltage Check all electrical connections to the
Operating 20% over voltage electrophoresis cell and whether the cell
contains the appropriate volume.
Then,press Start key to resume the run or,
to clear the error code, press any key
other than the Start or Stop key.
Check and replace U18 op amp
Replace power converter board
E15 Internal Short Circuit Check for and correct any short circuit or
Operating over 400 mA while excessive load problem.
under 6 volts. Then,press Start key to resume the run or,
This error condition may repre- to clear the error code, press any key
sent a short circuit. other than the Start or Stop key.

E16 Hardware failure Replace Power Converter Board.

E17 Hardware failure Replace Power Converter Board.
E98 Internal System Error Replace U11 or U16
ROM Error Replace Power Converter Board.
E99 Internal System Error Replace U11 or U16
RAM Error Replace Power Converter Board.

8.4 Test Point List

This section describes the testpoints designation and general purpose on the power converter board.

Testpoints Measurement Purpose

TP1 Main Ground Only connected to C53 and C54 for filter-
ing
TP2 Power Ground Not connected at neutral or earth poten-
tial. Use for primary AC measurements.
TP3 Signal Output Ground Use for output measurements
TP4 Signal Output Ground Use for output measurements
TP5 5 Volts DC Logic measurement
TP6 12 Volts DC Secondary Provides input to U8 - 5 volt regulator
TP7 12 Volts DC Secondary for Fan Fan measurement. Noisy measurement is
normal.
TP8 Power condition status is good Power to U19 and U11 flash ROM cir-
cuits is good.

100-2474B 04/03 8-5

Troubleshooting

8.5 LED Indicators

This section provides a table and location of the LED indicators on the Power Converter Board.

Table 1
LED Number Function
LED 8 High voltage AC output indica-
tor from bridge rectifier circuit
(D20)
LED 9 High voltage AC output indica-
tor from doubler circuit (D3)

LED 9

LED 8

Figure 8-1: LED Identification

8-6 100-2474B 04/03

 Parts Information

Section 9
Parts Information

9.1 Introduction
This section contains parts lists and associated information for the PowerPac Basic™. It provides instructions
for ordering and returning defective PowerPac Basic™ parts. This section also identifies parts that are field
replaceable.

9.2 Parts Orders - US Domestic Operations

Parts may be ordered through our Customer Service department. You can reach the Customer Service depart-
ment during regular office hours by calling 1-800-4BIO-RAD (1-800-424-6723), and selecting “1” for customer
service. If you do not have a touch tone phone, please stay on the line and an attendant will connect you. You
can help to make processing your order more efficient by having the following information before you call:
• The part number(s) or catalog number(s) of the parts you want to order
• Your company’s purchase order number
• Your customer account 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

100-2474A 09/02 9-1

Parts 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 international operations. These procedures vary depending
on your location

9.5 Recommended Spare Parts

The appropriate quantity for each of the PowerPac Basic™ spares will vary depending on the total quantity of
instruments in your installed base. A quantity of 1 for each field replaceable part is a good starting point.
Recommended Spares List

P a r t N u m b er De s c r ip t i on Photo

800-8683-01 TESTED POWER CONVERTER BOARD

ASSEMBLY

N/A DISPLAY BOARD ASSEMBLY

*Attached with Power Converter Board

800-7380 FAN ASSEMBLY

920-6961 FAN BOOT

9-2 100-2474A 09/02

 Parts Information

Recommended Spares List

P a r t N u m b er De s c r ip t i on Photo

900-5048 FUSE DRAWER

900-7283 2.5A, 250V 5 x 20 MM FUSE

920-6949 KEYPAD

800-6464 PROGRAMMMED PLCC P87C54SBAA

MICROPROCESSOR, U11

100-2474A 09/02 9-3

Parts Information

Recommended Spares List

P a r t N u m b er De s c r ip t i on Photo

920-6957 RED JACK

920-6962 BLACK JACK

920-6946 TOP COVER

920-6861 20 CONDUCTOR, 8 INCH RIBBON CABLE

9-4 100-2474A 09/02

 Parts Information

Recommended Spares List

P a r t N u m b er De s c r ip t i on Photo

920-6956 LIGHT PIPE

920-6973 18” X 24” AIR POLY PACKAGING BAG

910-2122 16.25” X 13.50” X 6.50” CARTON

9.6 Service Tools

The following tools are recommended for testing and servicing:

100-2474A 09/02 9-5

Parts Information

Recommended Tools List

Part Number Description Photo

Order from website at Clarostat Model 240C Power Resistor

www.clarostat.com Decade Box

Order from website at Fluke True RMS Multimeter Model 189

www.fluke.com

800-0838 High Voltage Test Cable Set

920-7369 Banana Plug Adaptor

9-6 100-2474A 09/02

 Drawings

Section 10
Drawings

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

10.2 System Diagrams

10.2.1 Power System Block Diagram

10.3 Assembly Drawings and Schematics

10.3.1 Schematics
• PowerPac Basic™ Power Supply - E8683 - 2 sheets

10.3.2 Assembly Drawings

• CPU Assembly 8006464
• Power Converter Board 8008683
• Molded Panel and Cover Parts 8006698

100-2474A 09/02 10-1

E8683B.sch-1 - Tue Jul 09 09:45:39 2002
E8683B.sch-2 - Tue Jul 09 09:45:54 2002
 8 7 6 5 4 3 2 1
REVISIONS
CHANGED CHECKED APPROVED
REV P.C.O.# DESCRIPTION OF CHANGE BY/DATE BY/DATE BY/DATE
EP EP RP
A L020598 NEW RELEASE 9-10-02 9-16-02 9-16-02

1
F
F

BLACK 8
E
E

3 4X CHAMFER MUST BE FACING UP

5
5
D RED D
RED
8 BLACK 9

CONTROLLED NETWORK COPY

C THIS DOCUMENT IS APPROVED FOR TOOLING,
PRODUCTION AND GENERAL DISTRIBUTION AFTER C
VERIFYING REVISION LEVEL IN ASK MANMAN.

NOTES: UNLESS OTHERWISE SPECIFIED:

7 1. PARTS MUST BE INSPECTED ACCORDING TO THE
SPECIFICATIONS IN THE INDIVIDUAL 920XXXX DRAWINGS.
2. ASSEMBLE AND PACKAGE PER THE FOLLOWING
PROCEDURES:
ASSEMBLE ITEMS 4 AND 7 INTO ITEM 3.
ASSEMBLE ITEMS 5 AND 8 (TWO OF EACH) INTO ITEM 1.
ASSEMBLE ITEM 6 (TWO EACH) INTO ITEM 2.
B ASSEMBLE ITEM 3 INTO ITEM 1 B
ASSEMBLE ITEM 9 INTO ITEM 2
ASSEMBLE ITEM 2 INTO ITEM 1 AND 3
3. ITEMS 1 AND 7 MUST BE COVERED WITH PROTECTIVE
2 MATERIAL TO PREVENT SCRATCHES.
4. PARTS SHALL BE FREE FROM NICKS, CUTS, OR
SCRATHCHES CAUSED BY THE ASSEMBLY, BAGGING, OR
PACKAGING PROCESS.

6
DRAWN BY/DATE
PTL 05-24-02
DO NOT SCALE PRINTS BIO-RAD LABORATORIES
UNLESS OTHERWISE SPECIFIED ALL 2000 ALFRED NOBEL DRIVE HERCULES, CA 94547
A CHECKED BY/DATE
EP 9-16-02
DIMENSIONS ARE IN INCHES. A
TOLERANCE
ENGR APPR/DATE
FRACTION .XX .XXX ANGLE
KIT, MOLDED PARTS
6 EP 9-16-02
MGMT APPR/DATE
.032 .01 .005 0 30"

RP 9-16-02
MATERIAL
THE INFORMATION CONTAINED IN THIS
DOCUMENT IS PROPRIETARY AND
CONFIDENTIAL. THIS DOCUMENT MAY NOT
POWERPAC BASIC
SEE NOTES BE COPIED OR REPRODUCED WITHOUT
WRITTEN PERMISSION FROM BIO-RAD. SIZE SCALE SHEET DRAWING NUMBER REV
FINISH
SEE NOTES SW DATA FILE: 8006698A.SLDDRW D 1:1 1 1 OF 8006698 A
8 7 6 5 4 3 2 1
 Appendix

Section 11
Appendix

11.1 System Checkout Test Certification Sheet

This section is the test certification sheet as performed in the System Checkout section. Successful completion
of the tests in the System Checkout section represents proper instrument performance.

100-2474A 09/02 11-1

Appendix

PowerPac Basic™
Test Certification Sheet

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

No Load Test ! Pass ! Fail
Overload Short Circuit Test ! Pass ! Fail
Sudden Load Change Test ! Pass ! Fail
Auto Power-On Test ! Pass ! Fail
Clarostat Model 240C Decade Box Check(Optional) ! Pass ! Fail

System Checkout 100V Constant Voltage Test-1200 ohm load ! Pass ! Fail
Output: Voltmeter Record______Current Meter Record______
Display: Voltage Display_______Current Display______

20V Constant Voltage Test-1200 and 500 ohm loads

Output: Voltmeter Record______Current Meter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display______
Output: Voltmeter Record______Current Meter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display___

150V Constant Voltage Test-1200 and 500 ohm loads

Output: Current meter Record______Voltmeter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display______
Output: Voltmeter Record______Current Meter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display___

11-2 100-2474A 09/02

 Appendix

280V Constant Voltage Test-1200 ohm load

Output: Current meter Record______Voltmeter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display______

170V Constant Voltage Test- 25K ohm load

Output: Current meter Record______Voltmeter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display______

290V Constant Voltage Test- 1200 ohm load

Output: Voltmeter Record______ ! Pass ! Fail
Display: Voltage Display_______

380 mA Constant Current Test- 500 ohm load

Output: Current meter Record______Voltmeter Record______ ! Pass ! Fail
Display: Voltage Display_______Current Display______

300V Burn-In Test- 30K ohm load

Start:
Output: Current meter Record______Voltmeter Record______
Display: Voltage Display_______Current Display______
End: 2 hours ! Pass ! Fail
Output: Current meter Record______Voltmeter Record______
Display: Voltage Display_______Current Display______

The above referenced instrument has been tested and meets all performance requirements.

Bio-Rad Labs Date

100-2474A 09/02 11-3

Appendix

11.2 Installation Check Sheet

This section is the installation check sheet as performed in the Installation section. Successful completion of
the installation in the Installation section represents a preliminary system checkout of the instrument.

PowerPac Basic™
Installation Check Sheet

Customer: Instrument Serial Number:

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

Test Specification Results

No signs of damage ! Pass ! Fail

All accessories received:

Visual Inspection PowerPac Basic unit
Power Cord ! Pass ! Fail
Fuses
Instruction Manual
Warranty Card

Startup Display ! Pass ! Fail

Fan Sound ! Pass ! Fail
Keypad illumination ! Pass ! Fail

Instrument Function Buffer Run ! Pass ! Fail

The above referenced instrument has been installed and meets installation and preliminary check requirements.

Bio-Rad Labs Date

11-4 100-2474A 09/02