Pace PRC 2000, Service Manual

Page 1: ...SERVICE MANUAL PRC 2000 SYSTEMS ...

Page 2: ...i MANUAL NO 5050 0344 REV C ...

Page 3: ...Vac PRC PRINT Pro Evac Redi Rak ResisTweez SensaTemp SMR Snap Vac Sodr Pen Sodr X Tractor SR 3 SR 4 ST StripTweez SwaPlater ThermoBand Thermo Drive ThermoJet ThermoPart ThermoPik ThermoTweez Tip Evac VisiFilter The following are trademarks and or servicemarks of PACE Incorporated Laurel Maryland U S A and may only be used to identify genuine PACE products or services Auto Off Cubby Vac Datastore D...

Page 4: ...ine Handpiece 23 Power Source 25 Calibration 30 Disassembly Assembly 32 Disassembly 32 Assembly 37 Flow Charts 39 Power 40 TMC 42 Pik Paste 44 MicroChine 46 Pulse Plate 48 Pulse Heat 50 Wiring Diagram 52 Multifunction PCB Assembly Schematic 54 Microprocessor PCB Assembly Schematic 60 Display PCB Assembly Schematic 64 Assembly Drawing 66 Air Hose Routing 68 Replacement Parts 69 Power Source 69 Powe...

Page 5: ... Figure 11 Thermocouple Attachment 31 Figure 12 Removing Rear Panel Screws 33 Figure 13 Removing Front Panel 34 Figure 14 Removing Bolt Assemblies 35 Figure 15 Removing Power Source From Case 36 Figure 16 Power Flow Chart 40 Figure 17 Thermal Management Center Malfunction Flow Chart 42 Figure 18 Pik Paste Malfunction Flow Chart 44 Figure 19 MicroChine Malfunction Flow Chart 46 Figure 20 Pulse Plat...

Page 6: ...ng MIL STD 2000A and WS 6536 EOS ESD and worldwide electrical codes NOTE Systems equipped with a special current limiting option 1 meg ohm tip to ground resistance comply with EN 100015 1 PACE refers to these systems as Soft Ground Systems The PRC 2000 system is available using power sources in either the 100 VAC version the 115 VAC version or the 230 VAC version The 230 VAC version system product...

Page 7: ...aximum HANDPIECES Set Temperature Range of SensaTemp Handpieces 38 C to 482 C 100 F to 900 F see note Digital Readout Resolution 1 C or F Tip Temperature Stability 1 1 C 2 F at idle from Set Tip Temperature NOTE True minimum and maximum Operating Tip Temperatures may vary depending on handpiece tip selection EOS ESD Tip To Ground Resistance Less than 5 ohms AC Leakage Less than 2 millivolts RMS fr...

Page 8: ...s loading to maximum torque Status LED Amber in color will cause the handpiece case to overheat Continuous heavy loading without a cooling period may cause damage to the handpiece and or the power source Shaft Run Out at Collet 13mm 0 005 inches TIR Total Indicator Reading max EOS ESD Tip To Ground Resistance Less than 5 ohms AC Leakage Less than 2 millivolts RMS from 50Hz to 500Hz min PULSE PLATE...

Page 9: ...ER SWITCH Turns system ON 1 and OFF 0 controls input power to the system 2 FOOT PEDAL SELECTOR SWITCH Control knob provides foot pedal connection to Pik and Paste PD MicroChine MC Pulse Plate PP or Pulse Heat PH features Figure 1 Power Switch Foot Pedal Selector Switch ...

Page 10: ...r outputs for Low Voltage Pulse Heat handpieces 4 PULSE HEAT OUTPUT CONTROL Controls low voltage AC power at PULSE HEAT Outputs 5 PULSE HEAT LED Illuminates Green in color when power is applied by foot pedal through FOOT PEDAL Selector Switch to the PULSE HEAT Outputs Figure 2 Pulse Heat Section ...

Page 11: ...ating system 7 PULSE PLATE OUTPUT CONTROL Controls DC power at PULSE PLATE Outputs 8 PULSE PLATE LED Illuminates Green to indicate when power is applied upon foot pedal actuation at the PULSE PLATE Outputs Illuminates Red if an overcurrent condition occurs during plating Figure 3 Pulse Plate Section ...

Page 12: ...500 10 000 RPMs of MicroChine handpiece 11 PROBE BRAKE RECEPTACLE Provides Probe Brake connection for the MicroChine Probe Brake feature See MicroChine portion of this manual for details 12 STATUS LED Illuminates Green to indicate MicroChine operation Illuminates Amber if maximum torque load is reached Illuminates Red to indicate braking status when Probe Brake circuit is activated Figure 4 MicroC...

Page 13: ...n TIMED CONT Switch is in the TIMED position 17 TIMED CONT SWITCH In CONT position continuous air pressure is delivered from PASTE DISP Port upon foot pedal actuation Foot Pedal Selector Switch in PD position In TIMED position measured interval of air pressure 0 1 10 seconds is delivered from PASTE DISP Port upon foot pedal actuation Foot Pedal Selector Switch in PD position 18 PASTE DISP LED Illu...

Page 14: ...9 GENERAL INFORMATION Figure 5 Pik And Paste Section ...

Page 15: ...ini ThermoJet handpiece and Sodr X Tractor handpiece in Hot Jet Mode 25 DIGITAL READOUT Provides a three digit display of the Current Channel channel with illuminated LED CH 1 CH 2 CH 3 or AUX 1 AUX 2 AUX 3 temperature information This includes Operating Tip Temperature in Temperature Display Mode normal operation Tip Temperature Offset Constant in TIP OFFSET Mode Set Tip Temperature in TIP SET Mo...

Page 16: ...ith a connected handpiece or auxiliary accessory 34 TIP SET KEY Allows the operator to adjust the Set Tip Temperature for the handpiece tip combination or Set Temperature for the auxiliary accessory connected to the Current Channel Places the THERMAL MANAGEMENT CENTER in the TIP SET Tip Temperature Set Mode 35 TIP SET LED Flashes when TIP SET Key is pressed indicating that the THERMAL MANAGEMENT C...

Page 17: ...fset Constant in TIP OFFSET Mode in one then ten degree increments Also used in CAL Calibration Mode 40 EARTH GROUND RECEPTACLE Provides positive earth ground to which a ground cable can be connected from the workpiece or work surface as part of a static control program Figure 6 Thermal Management Center Parts I D ...

Page 18: ...13 GENERAL INFORMATION ...

Page 19: ...ng circuitry and finger switch connection from THERMAL MANAGEMENT CENTER to the auxiliary accessory connected to Auxiliary Channel 1 Foot pedal attachment to this receptacle will allow vacuum pressure pump operation through foot pedal actuation 45 AUX 2 POWER RECEPTACLE Provides temperature control tip ground sensing circuitry and finger switch connection from THERMAL MANAGEMENT CENTER to the auxi...

Page 20: ...15 GENERAL INFORMATION Figure 7 Rear Panel Parts I D ...

Page 21: ...ation that if not closely followed might result in severe personnel injury or death Danger is not used for property damage unless personnel injury risk is present The purpose of this SAFETY section is to inform users of the heading guidelines used in this manual to indicate special Notes Cautions Warnings or Dangers Also included are recommended precautions which must be observed when operating or...

Page 22: ...ecautions when using materials e g fluxes solder paste Refer to the Material Safety Data Sheet MSDS supplied with each chemical and adhere to all safety precautions recommended by the manufacturer 4 The use of Safety Glasses is recommended when plating or machining NOTES 1 The solder collection chamber in the PACE Sodr X Tractor is made of glass Never remove this chamber using pliers Breakage of t...

Page 23: ... product should be performed by qualified service personnel only Line voltage parts will be exposed when equipment is disassembled Service personnel must avoid contact with these parts when troubleshooting the power source NOTES To insure continued peak performance use genuine PACE replacement parts ...

Page 24: ...res appear to be incorrect 5 DISASSEMBLY ASSEMBLY Contains Disassembly Assembly instructions which enables the technician to disassemble and assemble the unit properly 6 FLOW CHARTS SCHEMATICS Easy to follow Flow Charts Assembly Drawings Schematics and Wiring Diagrams which enable the technician to determine the source of a malfunction down to an assembly e g Main PCB Assembly level Locate the Flo...

Page 25: ... steps shown following a Handpiece Failures Replace VisiFilter if necessary clean heater bore and replace tip check air hose for holes and ensure that glass solder collection chamber Sodr X Tractor handpieces only is properly seated against heater seal b Unit Failures Remove the unit front panel see Disassembly Assembly Check internal hosing for kinks and replace internal VisiFilter attached to pr...

Page 26: ...tion marked FLOW IN facing you b Pull against one of the Wing Tabs while pulling on the Male Nib with the free hand to open the interconnection of the plastic housings at that Wing Tab c Pull against the second Wing Tab while pulling on the Male Nib to open the remaining interconnection and separate the plastic housings 5 Remove the old or discolored Element and discard 6 Insert the replacement Vi...

Page 27: ... resistance is low Solder short in Handpiece Remove Short Replace Heater Assembly Fuse F1 Shorted Heater Replace Heater Assembly Fuse F1 No Ground on Tip Check resistance Pin 4 to a NEW Tip Resistance should be less than 2 ohms If not Oxidation buildup in Heater Bore Clean Heater Bore using appropriate wire brush Defective Heater Replace Heater Assembly SENSATEMP HANDPIECES The following Heater As...

Page 28: ...23 REPAIR Figure 9 Connector Plug Wiring Figure 10 MicroChine Wiring MICROCHINE HANDPIECE ...

Page 29: ...in 4 with Finger Switch depressed If resistance is greater than 1 ohm Open Switch circuit Replace MicroChine Handpiece Check resistance Pin 3 to Pin 6 Resistance should be 3 to 40 ohms If not Defective Motor circuit Replace MicroChine Handpiece Motor runs continuously Check resistance Pin 1 to Pin 4 Resistance should read open circuit If not Shorted Finger Switch Replace MicroChine Handpiece No Gr...

Page 30: ... a time When defective handpiece is connected E code will be displayed Refer to handpiece Operation Manual No heat on SensaTemp handpiece s at Thermal Management Center Digital Readout displays very low temperature Open heater Refer to handpiece Operation Manual Blown 12 Amp Fuse Replace 12 amp Fuse located on rear of Power Source Disconnect all SensaTemp handpieces before powering system up Plug ...

Page 31: ...ug Repair Foot Pedal if defective Defective Motor Pump Replace Motor Pump Microprocessor pcb defect Replace Microprocessor pcb Keys on Thermal Management Center don t function properly Key caps binding Clean and or adjust Key caps Display pcb misaligned or defective Replace Display pcb Microprocessor pcb defect Replace Microprocessor pcb Cannot adjust Offset or Set Tip Temperature on Thermal Manag...

Page 32: ...is normal Low AC line voltage Check line voltage Display pcb defect Replace Display pcb Microprocessor pcb defect Replace Microprocessor pcb Paste dispenser pressure is insufficient or nonexistent Poor air hose connections Check air hose connections outside and inside of system power source Clogged air filter Replace filter Defective pump valve or reservoir Replace defective part Excessive noise d...

Page 33: ...turely Probe Brake test lead is connected to or exciting a circuit having less than 500 ohms resistance to ground Remove ground lead from pcb MicroChine continues to run after release of finger switch or foot pedal Defective MicroChine handpiece Refer to Table II to check MicroChine handpiece Replace MicroChine handpiece if defective MicroChine Probe Brake reacts sluggishly or is inoperable Probe ...

Page 34: ...re output on power source rear panel is obstructed Remove obstruction Defective Pik Vac pump assembly Replace Pik Vac pump Pulse Heat handpieces do not heat Pulse Heat LED is illuminated Green in color Loose connection at Pulse Heat Outputs or handpiece connector Tighten connections Defective Universal Power Cord Check voltage at Pulse Heat Outputs Replace Universal Power Cord if defective Multifu...

Page 35: ...e available tips PACE uses with and without embedded thermocouples a Use PACE part number 7021 0004 P1 tip with embedded thermocouple or tip only part number 1121 0337 on handpieces with 4 76 mm 3 16 inch heater bore b Use PACE part number 7021 0003 P1 tip with embedded thermocouple or tip only part number 1121 0130 on handpieces with 3 18 mm 1 8 inch heater bore NOTE When using tips with embedded...

Page 36: ...le 3 Wedge the thermocouple into place using the copper wedge or bare copper wire The thermocouple should be wedged as air tight as possible TIP TEMPERATURE TEST 1 Install the tip into the handpiece to be tested with the end of the tip properly seated The recommended PACE tips are shown extending out of the heater 9 5mm 3 8 inch 2 Connect the free end of the thermocouple wire to the PACE Process M...

Page 37: ...he power source from the chassis WARNING POTENTIAL SHOCK HAZARD The following procedures are to be performed by qualified service personnel only Removal of the Power Source panels exposes line voltage parts Service personnel must insure that the AC Power Cord is disconnected prior to disassembly 1 Place the unit on a suitable work surface Insure that the Power Cord has been disconnected from the b...

Page 38: ... Removing Rear Panel Screws 2 Position the PRC 2000 power source with the rear panel facing forward 3 Remove the 3 rear panel mounting screws indicated on the rear panel DO NOT remove any other rear panel mounting screws ...

Page 39: ...4 Reposition the unit with the Front Panel of the Power Source facing forward 5 Remove the 10 Front Panel Mounting Screws 6 Pull the Front Panel forward 2 inches to expose the interior of the Power Source DO NOT disconnect any electrical or air hose connections ...

Page 40: ...ies 7 Locate the 4 Bolt Assemblies across the front inside bottom edge of the Power Source case 8 Loosen each of the Hex Nuts on the 4 Bolt Assemblies 9 Slide each of the Bolt Assemblies forward and remove the assemblies from the Power Source ...

Page 41: ...ping 2 of the metal posts which connect the pc boards to the power source chassis Pull the power source forward and out of the case 11 Set the case aside 12 The unit can now be connected to the house AC supply to troubleshoot the system Figure 15 Removing Power Source From Case ...

Page 42: ...e power source with the rear panel facing forward Reinstall the 3 rear panel mounting screws 5 Reposition the power source with the front panel facing forward Reinstall the 4 bolt assemblies Tighten the hex nuts on each bolt assembly to secure the power source in position 6 Insure that all air hoses are properly connected to the front panel Refer to the Air Hose Routing illustration 7 Install the ...

Page 43: ...38 REPAIR ...

Page 44: ...to use begin with the Power flow chart which will direct you to the area of concern Insure that the power source has been removed from its case before performing the applicable procedure WARNING POTENTIAL SHOCK HAZARD The following Flow Chart procedures are to be performed by qualified service personnel only Line voltage parts are exposed Service personnel must avoid contact with these parts when ...

Page 45: ...40 REPAIR POWER Figure 16 Power Flow Chart ...

Page 46: ...41 REPAIR ...

Page 47: ...42 REPAIR TMC Figure 17 Thermal Management Center Malfunction Flow Chart I ...

Page 48: ...43 REPAIR ...

Page 49: ...44 REPAIR Figure 18 Pik Paste Malfunction Flow Chart PIK PASTE ...

Page 50: ...45 REPAIR ...

Page 51: ...46 REPAIR Figure 19 MicroChine Malfunction Flow Chart MICROCHINE ...

Page 52: ...47 REPAIR ...

Page 53: ...48 REPAIR PULSE PLATE Figure 20 Pulse Plate Malfunction Flow Chart ...

Page 54: ...49 REPAIR ...

Page 55: ...50 REPAIR PULSE HEAT Figure 21 Pulse Heat Malfunction Flow Chart ...

Page 56: ...51 REPAIR ...

Page 57: ...52 REPAIR Figure 22 PPS 400 PPS 400J PPS 400E Wiring Diagram WIRING DIAGRAM ...

Page 58: ...53 REPAIR ...

Page 59: ...54 REPAIR MULTIFUNCTION PCB ASSEMBLY SCHEMATIC Figure 23 Multifunction PCB Assembly Schematic Sheet 1 of 3 ...

Page 60: ...55 REPAIR ...

Page 61: ...56 REPAIR MULTIFUNCTION PCB ASSEMBLY SCHEMATIC CONT D Figure 23 Multifunction PCB Assembly Schematic Cont d Sheet 2 of 3 ...

Page 62: ...57 REPAIR ...

Page 63: ...58 REPAIR MULTIFUNCTION PCB ASSEMBLY SCHEMATIC CONT D Figure 23 Multifunction PCB Assembly Schematic Cont d Sheet 3 of 3 ...

Page 64: ...59 REPAIR ...

Page 65: ...60 REPAIR MICROPROCESSOR PCB ASSEMBLY SCHEMATIC Figure 24 Microprocessor PCB Assembly Schematic Sheet 1 of 2 ...

Page 66: ...61 REPAIR ...

Page 67: ...62 REPAIR MICROPROCESSOR PCB ASSEMBLY SCHEMATIC CONT D Figure 24 Microprocessor PCB Assembly Schematic Cont d Sheet 2 of 2 ...

Page 68: ...63 REPAIR ...

Page 69: ...64 REPAIR Figure 25 Display PCB Assembly Schematic DISPLAY PCB ASSEMBLY SCHEMATIC ...

Page 70: ...65 REPAIR ...

Page 71: ...66 REPAIR ASSEMBLY DRAWING Figure 26 Assembly Drawing ...

Page 72: ...67 REPAIR Figure 27 Assembly Drawing Cont d ...

Page 73: ...68 REPAIR AIR HOSE ROUTING Figure 28 Air Hose Routing ...

Page 74: ...0 0073 6020 0073 12 Pressure Reservoir 1140 0034 1140 0034 13 Solenoid 12 Volt 1194 0016 1194 0016 14 VisiFilter External installed between Snap Vac Port handpiece air hose 1309 0028 1309 0028 15 VisiFilter Replacement Elements 1309 0027 P50 1309 0027 P50 16 VisiFilter Internal located inside power source 1309 0020 1309 0020 POWER SOURCE Listed below are the power source parts which may be ordered...

Page 75: ...70 REPLACEMENT PARTS Figure 29 Power Source Replacement Parts POWER SOURCE CONT D ...

Page 76: ...71 REPLACEMENT PARTS Figure 30 Power Source Replacement Parts Cont d ...

Page 77: ...72 REPLACEMENT PARTS Figure 31 Power Source Replacement Parts Cont d ...

Page 78: ...perature Chart Holder Assembly 1257 0186 P1 7 Cleaning Station Complete 6021 0006 8 Fiber Cleaning Tool 1100 0232 9 Fiber Filler Replacement 1127 0013 10 Sponge Cleaning Tool 1100 0233 11 Sponge Filler Replacement 4021 0006 12 SX Tip Tool Stand for air handpieces 6019 0044 13 SP Tip Tool Stand for SP handpieces 6019 0043 14 ThermoTweez Tip Tool Stand 6019 0046 15 Paste Dispenser Cubby 6019 0038 16...

Page 79: ...mbly 6010 0074 P1 9 Glass Chamber 1265 0009 P1 10 Filter 1309 0018 11 Heater Set Screw 1348 0547 12 SP 2A Sodr Pen Soldering Iron Handpiece 54 Watts 6025 0014 P1 13 Heater Assembly 6010 0086 P1 14 Heater Set Screw 1348 0547 15 SP 1A Sodr Pen Soldering Iron Handpiece 37 Watts 6025 0013 P1 16 Heater Assembly 6010 0085 P1 17 Heater Set Screw 1348 0547 18 TJ 70 Mini ThermoJet Handpiece 7023 0002 P1 19...

Page 80: ...rip Kit 6993 0155 33 Replacement Pads For Cushion Grips 1317 0029 P2 34 Tip Alignment Tool 1100 0234 35 PV 65 Pik Vac Handpiece 7027 0001 P1 36 Metal Tip 45 Angle 1121 0413 P5 37 Vacuum Cups Tips See TP 65 Handpiece 38 MC 65 MicroChine Handpiece 7026 0001 P1 39 Probe Brake Patch Cord 1332 0159 40 Deluxe Tool Kit 6005 0013 PULSE HEAT HANDPIECES 41 CT 15 ConducTweez Handpiece 7020 0001 P1 42 TW 15 R...

Page 81: ...ng Silicone Translucent 54 Lg 1342 0001 13 6 Hose Clamps 1321 0085 01 P6 7 Cable Marker Kit 6993 0136 8 Quick Change Hose Mount Female 1259 0086 9 Quick Change Hose Mount Male 1259 0087 10 Bristle Brush 1127 0002 11 Wire Brush 3 16 Diameter 1127 0014 12 Wire Brush 1 8 Diameter 1127 0006 13 Tip Cleaner Kit 6993 0151 14 Tip Tool 1100 0206 15 PACE Screwdriver 1100 0230 HANDPIECE ACCESSORIES Table VII...

Page 82: ...Engineering Fax 301 604 8782 9893 Brewers Court Laurel MD 20723 1990 U S A Document Nbr 5050 0344 Revision Level C Date of Submission Nature of Change Identify page and paragraph and include proposed rewrite if possible Reason for Recommendation Submitter Name Company or Organization Mailing Address Telephone Include Area Code Voice Fax Thank you for your comments they are greatly appreciated MANU...