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PRC2000
Service Manual
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Service Manual
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Pace PRC2000 Service Manual

PRC 2000 SYSTEMS
SERVICE MANUAL
MANUAL NO. 5050-0344
REV. C
i
PACE Incorporated retains the right to make changes to specifications contained herein at any time, without notice.
The following are registered trademarks and/or servicemarks of PACE Incorporated, Laurel Maryland U.S.A. and may only be used to identify genuine PACE products or services:
AdapTip, Arm-Evac, Cir-Kit, ComForm I, ConducTweez, CRAFT, Dual Path, Flo-D-Sodr, FuseSet, HandiPik, HotSpot, LapFlo, MBT, Micro Portable, MicroChine, MiniChine, Mini-Wave, PACE, Pacenter, Ped-A-Vac, PETS, Pik-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, ThermoT weez, 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, Dust Evac, EKO, Lab Evac, MicroSpin, PaceLink, PaceNet, Pik & Paste, Prep-Set, Pulse Plate, Spa-Kleen, ThermoBond, TinSpin, TweezPik, Uni-Frame, V-A-N, Ventur-Evac.
Since 1958, PACE Incorporated has provided advanced technology training in all aspects of hand soldering, rework and repair.
Additional copies of this manual or other PACE literature may be obtained from:
PACE Incorporated (301) 490 - 9860 Sales Administration (301) 498 - 3252 Fax 9893 Brewers Court Laurel MD 20723-1990
©1995 PACE Incorporated, Laurel MD. All rights reserved. Printed in the U.S.A.
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TABLE OF CONTENTS
TITLE PAGE
General Information ............................................................................................................................................... 1
Introduction ................................................................................................................................................. 1
Specifications............................................................................................................................................... 1
Parts Identification....................................................................................................................................... 4
Safety .................................................................................................................................................................... 16
Heading Guidelines ................................................................................................................................... 16
Precautions................................................................................................................................................. 17
Repair ................................................................................................................................................................... 19
Repair Procedure ....................................................................................................................................... 19
Service Hints.............................................................................................................................................. 20
Corrective Maintenance............................................................................................................................. 21
VisiFilter Element Replacement .......................................................................................................... 21
SensaTemp Handpieces........................................................................................................................ 22
MicroChine 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
Power Source Accessories......................................................................................................................... 73
Handpieces................................................................................................................................................. 74
Handpiece Accessories .............................................................................................................................. 76
Manual Improvement & Comment Form ............................................................................................................ 77
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TABLES & FIGURES
TABLE PAGE
Table I Heater Assembly Checkout Procedures.......................................................................................... 22
Table II MicroChine Handpiece Checkout Procedures................................................................................ 24
Table III Corrective Maintenance, Power Source ......................................................................................... 25
Table IV Power Source Replacement Parts ................................................................................................... 69
Table V Power Source Accessories .............................................................................................................. 73
Table VI Replacement Handpieces................................................................................................................ 74
Table VII Replacement Handpiece Accessories ............................................................................................. 76
FIGURE PAGE
Figure 1. Power Switch/Foot Pedal Selector Switch ....................................................................................... 4
Figure 2. Pulse Heat Section ............................................................................................................................ 5
Figure 3. Pulse Plate Section............................................................................................................................ 6
Figure 4. MicroChine Section .......................................................................................................................... 7
Figure 5. Pik And Paste Section....................................................................................................................... 9
Figure 6. Thermal Management Center Parts I.D. ......................................................................................... 12
Figure 7. Rear Panel Parts I.D........................................................................................................................ 15
Figure 8. VisiFilter Element Replacement..................................................................................................... 21
Figure 9. Connector Plug Wiring ................................................................................................................... 23
Figure 10. MicroChine Wiring......................................................................................................................... 23
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 Plate Malfunction Flow Chart............................................................................................... 48
Figure 21. Pulse Heat Malfunction Flow Chart ............................................................................................... 50
Figure 22. PPS 400, PPS 400J, PPS 400E Wiring Diagram ............................................................................ 52
Figure 23. MultiFunction PCB Assembly Schematic ...................................................................................... 54
Figure 24. Microprocessor PCB Assembly Schematic .................................................................................... 60
Figure 25. Display PCB Assembly Schematic................................................................................................. 64
Figure 26. Assembly Drawing ......................................................................................................................... 66
Figure 27. Assembly Drawing Cont'd.............................................................................................................. 67
Figure 28. Air Hose Routing ............................................................................................................................ 68
Figure 29. Power Source Replacement Parts ................................................................................................... 70
Figure 30. Power Source Replacement Parts Cont'd........................................................................................ 71
Figure 31. Power Source Replacement Parts Cont'd........................................................................................ 72
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GENERAL INFORMATION
INTRODUCTION
The information contained in this manual will assist the technician in performing preventive maintenance and repair of the PACE PRC 2000 Systems. For details on operation of the system, refer to the System Operation & Maintenance Manual (PACE part number 5050-0313). If you encounter any difficulty operating or repairing your system, call PACE Customer Service directly at Tel. (301) 490-9860 or FAX (301) 604-9215.
The PRC 2000 is a Process Control System for Universal Assembly and Repair of Electronic Assemblies. The system combines the latest technology available for all types of component installation/removal, circuit board preparation and repair into one self-contained workstation.
The SR-4 “Safety Rating” designation on the back panel is your assurance that the PRC 2000 meets or exceeds all applicable civilian and military standards (including *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 (production as of Sept. 1995) bears the CE Conformity Marking which assures the user that it conforms to all the requirements of council directive EMC 89/336/EEC.
SPECIFICATIONS
POWER REQUIREMENTS
PPS 400 (PRC 2000 system): 115 VAC System - Operates on 97-127 VAC, 60 Hz. 400 Watts. PPS 400J (PRC 2000J system): 230 VAC System - Operates on 90-115 VAC, 50/60 Hz. 400 Watts. PPS 400E (PRC 2000E system): 100 VAC System - Operates on 195-264 VAC, 50/60 Hz. 400 Watts.
PHYSICAL PARAMETERS
Size: 35 cm W x 17.5 cm H x 23 cm D (13.75 in W x 6.9 in H x 9.25 in D) Weight: 13.6 Kg (30 Lbs)
ENVIRONMENTAL REQUIREMENTS
Ambient Operating Temperature: 0°C to 50°C (32°F to 120°F). Storage Temperature: -40°C to 100°C (-40°F to 212°F).
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GENERAL INFORMATION
THERMAL MANAGEMENT CENTER
VACUUM AND AIR
Measurements at Front Panel SNAP-VAC and PRESSURE Ports of power source.
Vacuum Rise Time : Evacuates 33 cc (2 cubic inch) volume
to 25 cm Hg. (10 in. Hg.) in 150 ms.
Vacuum: 51 cm Hg. (20 in. Hg.) (nominal) Pressure: .48 Bar (7 P.S.I.) (nominal, "MAX" setting) Air Flow: 13 SLPM (0.46 SCFM) maximum
HANDPIECES
Set T emperatur e 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.
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 from 50Hz to 500Hz.
PIK AND PASTE
Vacuum (at PIK-VAC Port): 7.6 cm Hg. (3 in. HG.) min.
Pressure (at PASTE DISP Port): 2.41 Bar (35 P.S.I.) min.
2
NOTE
MICROCHINE
HANDPIECE
Nominal Output Speed Range: 2,500 rpm, min. to 10,000 rpm, max.
Output T or que: 14 N•mm (2.0 inch-ounces), min. Speed Regulation: +10/-15% over Line/Load range of 0 to 14 N•mm (0 to 2 inch-ounces)
Duty Cycle: Application Dependent. Continuous loading to maximum torque (Status
Shaft Run-Out at Collet: .13mm (0.005 inches) TIR (Total Indicator Reading) max.
EOS/ESD
Tip-To-Ground Resistance: Less than 5 ohms.
GENERAL INFORMATION
from low line to high line voltage.
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.
AC Leakage : Less than 2 millivolts RMS from 50Hz to 500Hz, min.
PULSE PLATE
Output Voltage Range: 0 - 10 volts unfiltered, full wave DC.
PULSE HEAT
Output Voltage Range: 0 - 2.3 VAC RMS
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GENERAL INFORMATION
PARTS IDENTIFICATION
SYSTEM
1. POWER 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.
POWER SWITCH
Figure 1. Power Switch/Foot Pedal Selector Switch
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GENERAL INFORMATION
FRONT PANEL FEATURES
PULSE HEAT
3. PULSE HEAT OUTPUTS - Low voltage AC power 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
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GENERAL INFORMATION
PULSE PLATE
6. PULSE PLATE OUTPUTS - DC power connections for PACE SwaPlater plating 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
6
GENERAL INFORMATION
MICROCHINE
9. MICROCHINE POWER RECEPTACLE - Provides power, speed control, tip ground and finger switch connection for the MicroChine handpiece.
10. VARIABLE SPEED CONTROL - Controls motor speed (2,500 - 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. MicroChine Section
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GENERAL INFORMATION
PIK AND PASTE
13. PIK-VAC POWER SWITCH - Turns power "ON" (1) or "OFF" (0). Controls power to the Pik-Vac
vacuum pump.
14. PIK-VAC LED - Illuminates Green to indicate Pik-Vac vacuum pump operation.
15. PIK-VAC PORT - Quick connect fitting which provides vacuum for Pik-Vac handpiece.
16. PIK AND PASTE TIMER CONTROL - Determines variable time controlled shot (0.1 - 10 seconds)
of Paste Dispense (PASTE DISP) air pressure upon foot pedal actuation (Foot Pedal Selector Switch in PD position). Operates when 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 - Illuminates Green when air pressure is delivered from the PASTE DISP Port. Illuminates Yellow when the paste dispense pump reservoir is charging (no air pressure delivery from
P ASTE DISP Port).
19. PASTE DISP PORT - Quick connect fitting which provides air pressure (timed or continuous) to
dispensing barrel.
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GENERAL INFORMATION
Figure 5. Pik And Paste Section
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GENERAL INFORMATION
THERMAL MANAGEMENT CENTER
Refer to the illustration following for location of parts.
20. CH 1 POWER RECEPTACLE - Provides power, tip ground, sensing circuitry and finger switch connection from PRC 2000 system to handpiece connected to Channel 1 (CH 1).
21. CH 2 POWER RECEPTACLE - Provides power, tip ground, sensing circuitry and finger switch connection from PRC 2000 system to handpiece connected to Channel 2 (CH 2).
22. CH 3 POWER RECEPTACLE - Provides power, tip ground, sensing circuitry and finger switch connection from PRC 2000 system to handpiece connected to Channel 3 (CH 3).
23. SNAP-VAC PORT - Quick connect fitting which provides quick-rise vacuum for Sodr-X-Tractor or ThermoPik handpieces.
24. CONTROLLABLE PRESSURE PORT - Quick connect fitting with adjustable valve which provides variable air flow for Mini 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 Mode, and other information in Calibration (CAL) Mode.
26. °F/°C KEY - Selects °F or °C display of Set and Operating Temperatures and Tip Temperature Offset Constants.
27. °F LED - Illuminates when Set and Operating Tip Temperatures and Tip Temperature Offset Constants are displayed in °F.
28. °C LED - Illuminates when Set and Operating Tip Temperatures and Tip Temperature Offset Constants are displayed in °C.
29. CH 1 LED - Illuminates when Channel 1 (CH 1) or Auxiliary Channel (AUX 1) is the Current Channel (i.e., the channel (with connected handpiece/tip or auxiliary accessory) whose temperature information is displayed on the Digital Readout).
10
GENERAL INFORMATION
30. CH 2 LED - Illuminates when Channel 2 (CH 2) or Auxiliary Channel (AUX 2) is the Current
Channel (i.e., the channel (with connected handpiece/tip or auxiliary accessory) whose temperature information is displayed on the Digital Readout).
31. CH 3 LED - Illuminates when Channel 3 (CH 3) or Auxiliary Channel (AUX 3) is the Current
Channel (i.e., the channel (with connected handpiece/tip or auxiliary accessory) whose temperature information is displayed on the Digital Readout).
32. AUX LED - Illuminates when an auxiliary channel (on system rear panel) is the Current Channel
(i.e., the channel (with connected handpiece/tip or auxiliary accessory) whose temperature information is displayed on the Digital Readout). One of the CH 1, CH 2 or CH 3 LEDs will illuminate simultaneously with the Auxiliary LED to indicate, respectively, which of the auxiliary channels is active (AUX 1, AUX 2 or AUX 3).
33. CH SELECT KEY - Selects the Current Channel (among “Active Channels” i.e., those with 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 CENTER is in TIP SET Mode.
36. TIP OFFSET KEY - Allows the operator to adjust the TIP OFFSET CONSTANT for the handpiece or auxiliary accessory connected to the Current Channel. Places the THERMAL MANAGEMENT CENTER in the TIP OFFSET (Tip Temperature Offset) Mode.
37. TIP OFFSET LED - Flashes when TIP OFFSET Key is pressed indicating that the THERMAL MANAGEMENT CENTER is in the TIP OFFSET Mode. Remains illuminated (not flashing) in
Temperature Display Mode (normal operating mode) when a Tip Temperature Offset Constant of greater than “3” for °C (“6” for °F) is entered.
38. SCROLL UP KEY - Increases the Set Tip Temperature (in TIP TEMPERATURE SET Mode) and Tip Temperature Offset Constant (in TIP TEMPERATURE OFFSET Mode) in one, then ten degree increments. Also used in “CAL” (Calibration) Mode.
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GENERAL INFORMATION
39. SCROLL DOWN KEY - Decreases the Set Tip Temperature (in TIP SET Mode) and Tip Temperature Offset 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.
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GENERAL INFORMATION
13
GENERAL INFORMATION
REAR PANEL
41. AC POWER RECEPTACLE/FUSE HOLDER - Receptacle for providing power to the PRC 2000 system from AC outlet through power cord. Also location of fuse (F1) which protects the system from overcurrent conditions.
42. FUSE F1 - Provides overload protection for PRC 2000 system.
43. FOOT PEDAL RECEPTACLE - Input for foot pedal which operates the Pik and Paste, MicroChine,
Pulse Plate or Pulse Heat features of the system as determined by the FOOT PEDAL Selector Switch. This receptacle is not connected to the Thermal Management Center controls.
NOTE
The Auxiliary Power Receptacles listed below (items 44-46) will provide temperature control for line operated auxiliary accessories or foot pedal operation only. SensaTemp handpieces will not function properly if connected to these outputs.
44. AUX 1 POWER RECEPTACLE - Provides temperature control, tip ground sensing 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 auxiliary accessory connected to Auxiliary Channel 2. Foot pedal attachment to this receptacle will allow vacuum/ pressure pump operation through foot pedal actuation.
46. AUX 3 POWER RECEPTACLE - Provides temperature control, tip ground sensing circuitry and finger switch connection from THERMAL MANAGEMENT CENTER to the auxiliary accessory connected to Auxiliary Channel 3. Foot pedal attachment to this receptacle will allow vacuum/ pressure pump operation through foot pedal actuation.
47. FUSE F2 - Provides overload protection for CH 1, CH 2 and CH 3 power receptacles.
48. PIK PRESSURE PORT - Low pressure output with quick connect fitting. Controlled by PIK-VAC
Power Switch (front panel).
14
GENERAL INFORMATION
Figure 7. Rear Panel Parts I.D.
15
SAFETY
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 servicing this product.
HEADING GUIDELINES
PACE adheres to the following Heading Guidelines (based on OSHA guidelines) when listing special information or precautions to be taken. Especially important are all procedures and practices which, if not strictly observed, could result in injury or loss of life. These "NOTES", "CAUTIONS","WARNINGS" and "DANGERS" are inserted in this manual whenever deemed necessary. They appear in a blocked off form with double outline and a shaded background to highlight the information as shown below.
NOTE
XXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXXX
NOTE
Used to indicate a statement of company recommendation or policy. The message may relate directly or indirectly to the safety of personnel or protection of property. NOTE is not associated directly with a hazard or hazardous situation and is not used in place of "CAUTION", "WARNING" or "DANGER".
CAUTION
Used to indicate a hazardous situation which may result in minor or moderate injury. May also be used to alert personnel to conditions, procedures and practices which, if not observed, could result in damage to or destruction of the product or other equipment.
WARNING
Used to define additional information that if not closely followed might result in serious damage to equipment and represent a potential for serious personnel injury.
DANGER
Defines additional information 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.
16
SAFETY
PRECAUTIONS
The following are general safety precautions which personnel must understand and follow when using or servicing this product. These precautions may or may not be included elsewhere in this manual.
USEAGE PRECAUTIONS
CAUTIONS
1. SensaTemp handpiece heaters and installed tips are hot when handpiece is powered on. DO NOT touch either the heater or tip. Severe burns may result! Always store handpiece in the appropriate cubby when not in use.
2. Always use this system in a well ventilated area. A fume extraction system such as those available from PACE are highly recommended to protect personnel from solder flux fumes.
3. Exercise proper precautions 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 the chamber may result. Always remove using the procedures recommended by PACE in the associated handpiece manual.
2. The glass solder collection chamber in the PACE Sodr-X-Tractor is hot when the handpiece is in use. When removing the chamber for cleaning, never touch the glass with bare hands. Allow the chamber to cool before cleaning.
3. Disconnect the MicroChine handpiece from the power source or turn the power switch off before installing or changing tools.
17
SAFETY
SERVICING PRECAUTIONS
DANGERS
POTENTIAL SHOCK HAZARD - Repair procedures performed on this 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.
18
REPAIR
REPAIR PROCEDURE
The "REPAIR" section of this manual provides the technician with the information necessary to determine the source of a malfunction and take the necessary steps to correct it. In order to perform the most expedient repair, the technician must follow the process listed below step by step, in order. Failure to do so will make the diagnosis and repair much more difficult.
1. PERIODIC MAINTENANCE - No periodic or special maintenance is required on this system.
2. SERVICE HINTS - Read these helpful hints which give information on operation and troubleshooting.
3. CORRECTIVE MAINTENANCE - A guide for resolving malfunctions caused by improper maintenance or handpiece failure. Locate the "Symptom" in the "Corrective Maintenance" section which best describes the malfunction of the failed unit. Check each point described under "Solution" in order of listing.
4. CALIBRATION - Lists procedures for performing tip temperature tests to check handpieces. Perform these procedures periodically or if operating tip temperatures 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 Flow Chart which best describes the malfunction of the failed unit. Follow the instructions on the Flow Chart and perform the checks indicated to determine the source of the malfunction. The schematics shown are for systems produced at the time of publication of this manual. If any variances in components or wiring are detected on your system contact PACE Customer Service for assistance (see step #7 below).
7. PACE CUSTOMER SERVICE - If the cause for the malfunction has not been determined at this point, call PACE Customer Service at TEL:(301) 490-9860, FAX (301) 604-9215.
WARNING
POTENTIAL SHOCK HAZARD Repair Procedures are to be per-
formed 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.
19
REPAIR
SERVICE HINTS
1. OPERATIONAL PROBLEMS: Refer to the PACE Operation & Maintenance Manual (P/N 5050-
0313) for complete operational instructions on use of this product. If a Password has been installed by the system user, remove the Password before proceeding with the repair. The user can reinstall the Password after the system is repaired.
2. VACUUM FAILURES: Failures of this nature can be caused by either the unit or the SensaTemp
handpiece. Remove the Air Hose (and attached VisiFilter) from the SNAP-VAC Port and check for vacuum at the port. If sufficient vacuum is present, the malfunction exists in the handpiece. Further, if vacuum is sufficient at the port, check the vacuum level at the end of the glass solder collection chamber (Sodr-X-Tractor handpieces only, chamber must be checked cold). Take the applicable 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 pressure port on motor pump assembly).
3. HEATING CONTROL CIRCUITS: Must be checked under load (with handpiece/s plugged in). The output(s) are obtained by switching triacs on and off. The voltage level to the handpiece(s) does not change when adjusting the Set Tip Temperature. The control circuit of the unit varies the duty cycle of voltage application as required to achieve and maintain the set temperature of the handpiece.
4. HEATING FAILURES: Usually caused by defective SensaTemp handpiece heaters. Refer to the "Heater Assembly Checkout Procedures", Table I. When checking the system power source, use a known good handpiece.
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