Pace PRC 2000 User manual

SERVICE MANUAL
PRC 2000 SYSTEMS

i
MANUAL NO. 5050-0344
REV. C

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©1995 PACE Incorporated, Laurel MD. All rights reserved. Printed in the U.S.A.
PACE Incorporated retains the right to make changes to specifications contained herein at any time, without
notice.
Contact your local authorized PACE Distributor or PACE Incorporated to obtain the latest specifications.
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,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, 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

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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

1
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. [phone] or FAX [phone].
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 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 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.

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GENERAL INFORMATION
MICROCHINE
HANDPIECE
Nominal Output
Speed Range: 2,500 rpm, min. to 10,000 rpm, max.
Output Torque: 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)
from low line to high line voltage.
Duty Cycle: Application Dependent. Continuous 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
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
POWER
SWITCH
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.
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

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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 DISPLED - 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
PASTE 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).

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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 TIPTEMPERATURE 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

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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).

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GENERAL INFORMATION
Figure 7. Rear Panel Parts I.D.