GbX® Backplane and Daughtercard Tooling *GbX is a Trademark of Amphenol Corp. GbX BACKPLANE and DAUGHTERCARD INSTALLATION and REPAIR TOOLING Order No. 62202-2099 Operation Manual Description Operation Maintenance Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 1 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling WARNING NEVER OPERATE, SERVICE, INSTALL, OR ADJUST THIS TOOL WITHOUT PROPER INSTRUCTION AND WITHOUT FIRST READING AND UNDERSTANDING THE INSTRUCTIONS IN THIS MANUAL. WORK SAFELY AT ALL TIMES For Service, Contact Your Local Molex Sales Office Molex Application Tooling Group 2200 Wellington Court Lisle, Illinois 60532 Tel: 630-969-4550 Fax: 630-505-0049 Visit our Web site at http://www.molex.com Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 2 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Table of Contents SECTION 1 General Description and Available Presses 2 Installation and Operation 3 Maintenance, Spare Parts, Perishable Parts and Problem Checklist 4 Available Tooling 5 Repair and Replacement Procedures Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 3 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Section 1 General Description and Available Presses 1.1 Description 1.2 Features 1.3 Technical Specifications 1.4 Delivery Check 1.5 Tools 1.6 Press Requirements Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 4 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling General Description 1.1 Description This manual covers the tooling available to press Molex GbX® Back plane Power Modules, Back plane Connectors, and Daughtercard Modules into printed circuit boards. Repair tools and custom tools are also covered. The tooling is designed to go into a flat platen press. Operation is simple: Position a printed circuit board on the customer supplied support. Then manually insert a connector(s) into the pc board. Position the loading head into the connector. Actuate the press to press the connector pins into the board. 1.2 Features The press-in tooling is designed so that one module will press in one connector, or several modules can be mounted in a tool holder and be used to press in any combination of connectors in one operation. See Section 4-2 (Ordering Instructions) for details. 1.3 Technical Specifications Dimensions and Weight The dimensions and weight depend on the tooling used and the size of the pc board support. Rate 90 connectors pressed in (one at a time) per hour depending on operator skill. 1.4 Delivery Check Carefully remove the tooling from its shipping container and check to be sure what was received matches the purchase order and no damage has occurred. 1.5 Tools A metric hex wrench set will be required to assemble or disassemble tooling mounted in rails. Molex Presses Molex offers a press that is suitable for this application. It is: 62201-3800 8-ton Pneumatic Flat Platen Press See Figure 1-1. 1.6 Press Requirements This tooling is designed to fit in a flat platen (or flat rock) press, capable of 66N (15 lbs) of force per pin. Letter Description (See Figure1-3) Dimension (min) A Upper Platen B C Opening Throat 51by 102 by 25.4mm (2 by 4 by 1”) 89mm (3.5”) 150mm (6”) A B C Figure 1-3 PRESS THROAT DIMENSIONS Figure 1-1 62202-3800 8-TON PRESS Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 5 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Section 2 Installation and Operation 2.1 Backup for printed circuit boards 2.2 Press stroke adjustment 2.3 Installation 2.4 Operation Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 6 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 2.1 Printed Circuit Board Support The GbX® tooling requires up to 10 lb. per pin of force to press the connectors into the printed circuit boards. Therefore, a backup or support is required to prevent damage to the P.C. board. The support fixture should have clearance for the connector terminals when they protrude through the underside of the P.C. board. It is also recommended that the support fixture have locating pins. Due to the custom nature of each application, Molex does not supply support and locating fixtures, the customer normally supplies them. 10. Press the connector into the P.C. board and observe for any deflection of the board when the ram is at the bottom of its stroke. 2.2 Press Stroke Adjustment Most presses have some means of adjusting the stroke; please refer to the appropriate manual (for the press being used) for press stroke adjustments. The stroke should be adjusted so that when the press ram stops in the down position, the bottom of the connector is flush to .25mm (.010 in.) above the surface of the P.C. board. See Figure 2-1. .25mm (.010 in.) Max. The following is one simple way of making a P.C. board support and locating fixture: 1. Locate a suitable piece of material for the backup. It should be approximately 3/4 inch thick and same size or a little larger than the printed circuit board to be used. While aluminum could be used, a rigid nonconductive material such as a phenolic is preferred. (A stack of scrap P.C. boards of suitable size could be fastened together and used.) 2. Obtain a scrap P.C. board like the ones to be assembled. Attach this board to the material from step 1. 3. Using an oversize drill bit, drill through each hole where a pin from the connector will go. Drill deep enough into the lower material to be certain the pins do not bottom out when inserted (at least 5mm [0.20in] deep). 4. Locate two (2) holes on the P.C. board to use as locating points. Drill for and mount suitably sized dowel pins in these two locations on the support fixture. 5. Clear out the support for any components mounted on the underside of the printed circuit board. 6 Place a P.C. board on top of the support, located by the two pins, and check that the holes for the connector pins are aligned. 7. Pre-insert a connector in the P.C. board in the correct position. 8. Insert the press-in tool of proper size into the connector. 9. Place the support with the P.C. board under the press ram. Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 Figure 2-1 MAXIMUM CLEARANCE WHEN CONNECTOR FULLY SEATED 2.3 Installation The only installation required is when you need to install insertion modules into a tooling holder. To do this, use the following procedure: 1. Along the lower edge of the tooling holder is a row of M3 set screws, (See Figure 2-2), back these out so that they do not protrude into the inside of the holder. KEYWAY Figure 2-2 TOOLING HOLDER M3 SET SCREW 2. Slide the insertion modules into the tooling holder in the proper order. See Figure 2-3. The modules are keyed so that they cannot be put in backwards. UNCONTROLLED COPY Page 7 of 28 GbX® Backplane and Daughtercard Tooling *GbX is a Trademark of Amphenol Corp. HOLDER TYPICAL INSERTION MODULES Figure 2-3 MOUNTING INSERT MODULE IN A MOUNTING BLOCK 3. Now tighten the M3 set screws against the modules with one (1) screw against each power module inserter, two (2) screws evenly spaced on a 10 wide header insertion module and at least three (3) screws evenly spaced on a 25 wide header insertion module. Figure 2-4 shows a typical completed assembly. Figure 2-5 ALIGNING TERMINAL PINS TO HOLES 2. Locate the pre-loaded board into the support pallet. See Figure 2-6. LOCATING PIN PC BOARD LOCATING PIN CAUTION: Do not over tighten the setscrews; this could damage the insertion tool. NOTE: See Section 4 for details on selecting modules and mounting blocks. CONNECTOR ASSEMBLY SUPPORT PALLET Figure 2-6 CONNECTOR ASSEMBLY ON PC BOARD SUPPORT PALLET 3. Locate the tooling assembly in the connector assembly, carefully checking alignment. The orientation feature on the tool must engage with the notch on the connector body. See Figure 2-7. Figure 2-4 TYPICAL INSERTION TOOL ASSEMBLY 2.4 Operation Header insertion Tooling 1. Carefully locate the connector(s) on the printed circuit board and start in by hand. Make sure terminal pin 1 is in the correct position on all connectors. See Figure 2-5. Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 Figure 2-7 TOOLING LOCATED IN THE CONNECTOR ASSEMBLY UNCONTROLLED COPY Page 8 of 28 GbX® Backplane and Daughtercard Tooling 4. Position the pre loaded support pallet under the press platen. 5. Cycle the press. See Section 2.1 (Press Stroke Adjustment). 6. Remove the loaded support pallet. 7. Carefully remove the insertion tool assembly. Remove the printed circuit board. *GbX is a Trademark of Amphenol Corp. 3. Locate the P.C. board with the connector assembly on the user supplied support pallet. 4. Position the insertion tooling on the connector assembly. See Figure 2-9. PRESS-IN-TOOL PC BOARD Daughtercard Tooling Operation for inserting Daughtercard assemblies is different because Daughtercard connectors are available only in complete assemblies that are held together with a stiffener rail, so therefore, insertion tooling is only determined by the total assembly length. The insertion module is 100mm long and can be used alone or stacked in a tool holder for larger connector assemblies. 1. Locate the Daughtercard connector assembly on the printed circuit board. 2. Start the assembly into the board by hand. Check for proper seating and bent pins under the assembly after pre loading on to the P.C. board. See Figure 2-8. STIFFENER RAIL SIGNAL MODULE (11) ALIGNMENT BLOCK POWER MODULE LOCATING PIN LOCATING PIN CONNECTOR ASSEMBLY SUPPORT PALLET Figure 2-9 PC BOARD, CONNECTOR, AND TOOLING ON SUPPORT PALLET READY FOR PRESS 5. Position the P.C. board and support fixture under the press platen. 6. Cycle the press. 7. Remove the loaded support pallet from the press. 8. Remove the insertion tool. 9. Carefully remove the assembled printed circuit board from the support pallet. PC BOARD Figure 2-8 TYPICAL DAUGHTERCARD ASSEMBLY ON THE PC BOARD Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 9 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Section 3 MAINTENANCE 3.1 Cleaning 3.2 Lubrication 3.3 Preventive Maintenance 3.4 Troubleshooting Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 10 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 3.1. Cleaning Once a day, the support fixture should be cleaned of dust and plating particles and other debris. Compressed air may be necessary to remove debris from the pin clearance holes. CAUTION: Use extreme caution when using compressed air for cleaning as it can cause debris to get lodged in the tooling, and fly out at the operator. USE of proper safety glasses by the operator and onlookers is required. 3.2 Lubrication There is no lubrication required on any of the GbX® tooling. However, the presses each have their own requirements for lubrication and maintenance. The instruction manual for the specific press being used should be referred to. Molex provides a sheet for logging routine preventive maintenance in this section. 3.3 Preventive Maintenance DAILY: Clean, See Section 3.1 MONTHLY: Lubricate, See Section 3.2 CHECK SHEET MONTH___________YEAR_________ Week Daily Use Days of the Week MON TUE WED THU FRI SAT SUN Solution 1 2 3 4 Cleaning Lubricate Daily Monthly Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with the tool. Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 11 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 3.4 Troubleshooting Symptom Connector Being Damaged Doc. No: TM-622022099 Revision: H Cause Solution Press stroke set too low. Something not properly aligned. "Blades" on tooling bent or damaged. Release Date: 06-23-04 Revision Date: 01-28-11 Refer to the appropriate press manual and adjust the stroke. See Section 2.2. Check fixture and repair as required. Check alignment of fixture in press. Check to be sure the press platen is pressing squarely on the tooling block. Replace tool. UNCONTROLLED COPY Page 12 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Section 4 AVAILABLE TOOLS 4.1 Standard Press-In-Tools Table 4-1 Assembly Tooling for GbX® Signal Headers Table 4-2 Assembly Tooling for GbX® Daughtercard Receptacles Table 4-3 Standard Tool Holder for Back Plane Header Assembly Table 4-4 Field Repair Tooling for GbX® Backplane and Daughtercard Assemblies 4.2 Doc. No: TM-622022099 Revision: H Standard Tool Ordering Procedure Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 13 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 4.1 Standard Press-In-Tools Standard Insertion Tools All the applicable GbX® connectors and the standard tooling required for each connector are located in these tables. Table 4-1 Assembly Tooling for GbX® Signal Headers (For use in standard tool holders) Refer to the individual instruction sheets for more information on Individual tools. Product Number Tool Description Tool Size (Long) GbX® Signal Header (2 pair by 5 wide) (75827 series) Insertion Tool 62202-2810 9.25mm (.364”) GbX® Signal Header (2 pair by 10 wide) (75647, 75827, 75828, 75832, and, 75833 series) Insertion Tool 62202-2410 18.50mm (.728”) GbX® Signal Header (2 pair by 20 wide) (75647, and 75834 series) Insertion Tool 62202-2420 37.00mm (1.457”) GbX® Signal Header (2 pair by 25 wide) (75647, 75827, and 75832 series) Insertion Tool 62202-2430 46.25mm (1.82”) GbX-U™ Signal Header (2 pair by 45 wide) (76922 series) Insertion Tool 62202-3025 85.09mm (3.35”) GbX-U™ Signal Header (2 pair by 45 wide) (76922 and 76923 series) Insertion Tool 62202-3026 85.09mm (3.35”) GbX® Signal Header (3 pair by 5 wide) (75433 and 75836 series) Insertion Tool 62202-2500 9.25mm (.364”) GbX® Signal Header (3 pair by 10 wide) (75433, 75434, 75836, 75837, and 75844 series) Insertion Tool 62202-2510 18.50mm (.728”) GbX® Signal Header (3 pair by 25 wide) (75433, 75434, 75836, 75837, and 75844 series) Insertion Tool 62202-2530 46.25mm (1.821”) GbX® Signal Header (4 pair by 5 wide) (2.5mm) (75235 series) Wide Differential Insertion Tool 62202-2110 9.53mm (0.38”) Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Illustration Page 14 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Product Number Tool Description Tool Size (Long) GbX® Signal Header (4 pair by 7 wide) (2.5mm) (75235 series) Wide Differential Insertion Tool 62202-2120 12.7mm (0.50”) GbX® Signal Header (4 pair by 10 wide) (75831-All 4 pair series) (75235, 75838, and 75839 series) Insertion Tool 62202-2000 18.50mm (.728”) GbX® Signal Header “RE” Series (4 pair by 10 wide) 2.5mm (75644, 75870, 75871, and 75872 series) 2.5mm Pitch Insertion Tool 62202-2630 25.00mm (.984”) GbX® Signal Header (Double 4 pair by 10 wide) (75830-All 4 pair series) (75235, 75831, and 75839 series) *For two stacked 10’s only. Not for 20 wide discrete. Insertion Tool 62202-2010 37.00mm (1.457”) GbX® Signal Header (4 pair by 25 wide) (75235, 75466, and 75831 series) Insertion Tool 62202-2020 46.25mm (1.821”) GbX® Signal Header (5 pair by 10 wide) (75237, and 75848 series) Insertion Tool 62202-2030 18.50mm (.728”) GbX® Signal Header (Double 5 pair by 10 wide) (75237, and 75848 series) *For two stacked 10’s only. Not for 20 wide discrete. Insertion Tool 62202-2040 37.00mm (1.457”) GbX-U™ Signal Header (5 pair by 10 wide) (76922 series) Insertion Tool 62202-3030 20.32mm (0.80”) GbX-U™ Signal Header (5 pair by 10 wide) (76932 series) Insertion Tool 62202-3031 20.32mm (0.80”) GbX® Signal Header (5 pair by 25 wide) (75237, and 75848 series) Insertion Tool 62202-2050 46.25mm (1.821”) 2 pair by 5 wide L Series (75861, 75862, 75863and 75864 series) Insertion Module 62202-2440 9.25mm (.364”) 2 pair 10 wide L Series (75861, 75862, and 75863 series) Insertion Module 62202-2450 18.50mm (.728”) 2 pair 25 wide L Series (75861 and 75863 series) Insertion Module 62202-2470 46.25mm (1.821”) Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Illustration Page 15 of 28 GbX® Backplane and Daughtercard Tooling *GbX is a Trademark of Amphenol Corp. Product Number Tool Description Tool Size (Long) 3 pair by 5 wide L Series (75649, and 75858 series) Insertion Module 62202-2540 9.25mm (.364”) 3 pair 10 wide L Series (75467, 75649 and 75858 series) Insertion Module 62202-2550 18.50mm (.728”) 3 pair 25 wide L Series (75649 and 75858 series) Insertion Module 62202-2570 46.25mm (1.821 4 pair by 5 wide L Series (75465, 75466,75854, and 75856 series) Insertion Module 62202-2015 9.25mm (.364”) 4 pair 10 wide L Series (75465, 75466, 75854, 75855, 75856, and 75857 series) Insertion Module 62202-2025 18.50mm (.728”) 2 pair 1 up Power module (75492 series) Insertion Module 62202-2480 5.55mm (.219”) 2 pair 2 up Power module (75492 series) Insertion Module 62202-2485 12.95mm (.509”) 2 pair 3 up Power module (75492 series) Insertion Module 62202-2490 20.35mm (.801”) 3 pair 1 up Power module (75331 series) Insertion Module 62202-2580 5.55mm (.219”) 3 pair 2 up Power module (75332 series) Insertion Module 62202-2585 12.95mm (.509”) 3 pair 3 up Power module (75333 series) Insertion Module 62202-2590 20.35mm (.801”) 4 pair 1 up Power module (75341 series) Insertion Module 62202-2005 5.55mm (.219”) 4 pair 2 up Power module (75342 series) Insertion Module 62202-2060 12.95mm (.510”) Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Illustration Page 16 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Product Number Tool Description Tool Size (Long) 4 pair 3 up Power module (75343 series) Insertion Module 62202-2061 20.35mm (.801”) 5 pair 1 up Power module (75510,75512, 75513, 75514, 75515, 75516, 75517 75518,and 75519 series) Insertion Module 62202-2007 5.55mm (.219”) 5 pair 2 up Power module (75520,75524, 75526, 75527 and 75529 series) Insertion Module 62202-2062 12.95mm (.510”) 5 pair 3 up Power module (75530,75534, 75536, 75537 and 75539 series) Insertion Module 62202-2063 20.35mm (.801”) GbX® Signal Headers, 2,3,4, and 5 pair-closed end (All Headers with Guide/ Polarizer) Spacer Block 62202-2009 6.35mm (.250”) Illustration Table 4-2 Assembly Tooling for GbX® (Daughtercard Receptacles) Product Number Tool Description Tool Size (Long) 2 pair Daughtercard Insert (75650, 75676 series) Insertion Module 62202-2495 100mm 2 pair Ram Insert (75966 series) Insertion Module 62202-2496 100mm 3 pair Daughtercard Insert Insertion Module (75370, 75660, 75666 75876 and 75877 series) 62202-2595 100mm 4 pair Ram Insert (75717 series) Insertion Module 62202-2096 100mm 4 pair Daughtercard Insert (75220, 75420, 75426, and 75878 series) Insertion Module 62202-0214 100mm 5 pair Daughtercard Insert (75360 series) Insertion Module 62202-2008 100mm Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Illustration Page 17 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Table 4-3 Standard Tool Holder for Back Plane Header Assembly Tool Description Tool Length Tool Holder for Backplane Assembly Tooling 62201-9501 24mm Tool Holder for Backplane Assembly Tooling 62201-9502 72mm Tool Holder for Backplane Assembly Tooling 62201-9503 156mm Tool Holder for Backplane Assembly Tooling 62201-9504 216mm Tool Holder for Backplane Assembly Tooling 62201-9509 254mm Tool Holder for Backplane Assembly Tooling 62201-9511 304.8mm Tool Holder for Backplane Assembly Tooling 62201-9512 406.4mm Illustration Table 4-4 Field Repair Tooling for GbX® Backplane and Daughtercard Assemblies Tool Description Product Number Illustration Daughtercard Receptacles Stiffener Removal Tool GbX® 2 and 3 pair Assembly 62202-2300 (75370, 75650, 75660, 75666, 75676,and 75877 series) Daughtercard Receptacles/Ram GbX® 2 (75650, 75966) and 3 pair Assembly (75370, 75660, 75666, 75676, and 75877 series) Stiffener Removal Tool and Insertion Tool 62202-2900 Daughtercard Receptacles GbX® 4 and 5 pair Assembly (75360, 75420, 75426, 75878 series) Stiffener Removal Tool 62202-2070 Daughtercard Receptacles GbX® 4 pair (2.5mm) Assembly (75809 series) Stiffener Removal Tool 62202-2620 GbX® 4 pair Ram Assembly (75717 series) Stiffener Removal Tool 62202-2600 Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 18 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Product Number Tool Description Daughtercard Receptacles GbX® 2 pair Assembly (75650, 75676, and 75874 series) Wafer Removal Tool 62202-2083 Daughtercard Receptacles GbX® 2 pair Right Angle Male (RAM) Assembly (75966 series) Wafer Removal Tool 62202-2086 Daughtercard Receptacles GbX® 3, 4 and 5 pair Assembly (75220, 75360, 75370, 75420, 75426, 75660, 75666, 75876, 75877, 75878 series) Wafer Removal Tool 62202-2080 Backplane Headers Signal pins (All sizes) Signal Pair Inserter Repair Tool 62202-2090 Backplane Headers Shields (All sizes) Shield Removal Tool 62202-2100 Backplane Headers GbX-U™ (76922, 76923, 76932, and 76933 series) Removal Tool Backplane Headers 62100-9610 Backplane GbX-U™ (76922, 76923, 76932, and 76933 series) Signal Contact Insertion Tool 62100-5110 Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Illustration Page 19 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 4.2 Standard Tool Ordering Procedure Stacking Tooling All the insertion tooling listed in Table 4-1 and 4-2 can be stacked in any combination so as to be able to simultaneously press in any arrangement of stacked connectors. Tooling holders are available in various lengths. Figure 4-1 shows a typical setup for a 4 pair by 25 wide signal module and a one up power module in a standard tool holder. Ordering Tooling for Backplane Connectors In order to insert a typical row of backplane connectors, it is necessary to select the individual insertion tools and then pick the appropriate tooling holder (See example). Basic Procedure 1. Determine the combination of signal modules and power modules Figure 4-1 to be inserted. TYPICAL INSERTION 2. Select the proper insertion modules from Table 4-1 and Table 4-2. TOOL ASSEMBLY 3. Table 4-1 and Table 4-2 show the tool sizes. (L) Write down the length of each tool selected. NOTE: Make sure that if you require four of a particular tool, write down its length 4 times. NOTE: When using two 10 wide backplane insertion modules to press in a 20 wide header, only one module uses a side plate with a locating peg. On the second module, replace the pegged side plate with 62202-2003 un-pegged version. 4. Total up these lengths. 5. Using the length just calculated, select the next largest tooling holder from Table 4-3. The tooling holder can be shorter than the total tooling but not by more than 0.5 mm per side. 62202-0205 6. All of the tools selected above must be ordered separately. Example To be inserted: (1) 4 pair 25 wide Backplane Signal Module and (1) 4 pair 1 up Power Module. 1. Look at Table 4-1 and find the required tools. In this case it would be a 62202-2020 and a 62202-2005. 2. From Table 4-1 get the lengths of these tools. (Numbers may be rounded up) 62202-2020 =46.25mm and 62202-2005 = 5.55mm. 3. Add these two values for a total of 51.80mm. 4. From the Tooling Holder list in Table 4-3, pick the 72mm long holder, P.N. 62201-9502. 5. Thus the order to Molex should include the following: Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 62201-9502 62202-2020 Figure 4-2 EXAMPLE TOOL ASSEMBLY UNCONTROLLED COPY Page 20 of 28 GbX® Backplane and Daughtercard Tooling *GbX is a Trademark of Amphenol Corp. Quantity Order No. Description 1 62202-2020 4 pair by 25 wide Header Insertion Tool 1 62202-2005 4 pair 1 up Power mod. Insertion Module 1 62201-9502 72mm Long Tooling Holder (Figure 4-2 shows the assembled unit.) Ordering Daughtercard Tooling Daughtercard connectors only come in custom assemblies that are loaded in a stiffener rail. The daughtercard insertion modules are 100 mm long. Therefore, insertion tools can be used individually for connector assemblies that are shorter than 100mm. or stacked in a tool holder for connector assemblies that are longer. Basic Procedure 1. 2. Determine the combination of signal wafers and power modules to be inserted. Determine the total length of the stack of components. Using that length, select the DaughterCard insertion tools required to cover the whole connector assembly. If more than one 100mm module is used, a tool holder of appropriate length will be needed. This can be selected from Table 4-3. Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 21 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Section 5 Repair and Replacement 5.1 Backplane Repair Procedure 5.2 GbX® Backplane Shield Repair Procedure 5.3 Daughtercard Repair Procedure 5.4 Glossary of Terms Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 22 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 5.1 GbX® Backplane Repair Procedure: For the removal and replacement of Signal Pair pins. The following tools are required: Signal Pair Pin Replacement Tool 62202-2090 Shield Removal Tool 62202-2100 5/16” T-handle wrench * Needle nose pliers (miniature) * Tweezers * Plastic hammer * * Not supplied by Molex NEEDLE NOSE PLIERS CONNECTOR Removal SIGNAL PINS To remove damaged signal pins, grasp them with the needle nose pliers and pull straight up from the board. It is FIGURE 5-1 recommended that both pins in a pair be replaced. See Figure 5-1. In some cases it may be necessary to straighten a bent pin with the tweezers to allow access with the pliers. NOTE: Never reuse a backplane signal pin once it has been removed. Also, no more than three pins should be pressed into any plated through hole. Replacement To replace pairs of pins, use insertion tool no. 62202-2090. Note: The pins are left and right handed and must be loaded into the connector in their proper orientation. They should be positioned in the insertion tool so that the INSERTION ribs on the center of the pins are located in the TOOL grooves in the tip of the tool, facing the round 62202-2090 indentations. Due to the small size of the pins, a tweezers may help in this operation. There should be a slight friction fit when the pins are inserted all the way in to the tip. See Figure 5-2. Carefully load and push the pins down into the connector base until the tool stops against the board. See Figure 5-3. Then remove the inserter from the connector. CONNECTOR INSERTION TOOL 62202-2090 RIB OF PIN IN THE GROOVE OF TOOL SIGNAL PINS ROUND INDENTATIONS SIGNAL PINS Figure 5-3 Figure 5-2 Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 23 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling BACKPLANE SHIELDS 5.2 GbX® Backplane Shield Repair Procedure: CONNECTOR For the removal and replacement of Backplane Shield. The following tools are required: Shield Removal Tool 62202-2100 5/16” T-handle wrench * RETENTION FORKS OF THE SHIELD Plastic hammer * REMOVAL TOOL Appropriate signal insertion module (For shield replacement) * Not supplied by Molex The backplane shield removal tool will remove 10 to 25 wide shields, from 2, 3, 4, and 5 pair assemblies. NOTE: Never reuse a backplane shield once it has been removed. MAKE SURE THERE IS NOT DEBRIS IN THIS AREA Figure 5-4 Removal Preset the shield removal tool so the retention grippers are fully extended and there is no debris in the area shown in Figure 5-4. Insert the tip of the removal tool into the connector with the grippers over the shield to be removed. Be careful not to damage the metallic parts in the connector. Insert a 5/16“ T-handle (not supplied with this tool) into the socket head screw on the top of the tool, (See Figure 5-5) and rotate clockwise until the tool grips the shield. Then continue to turn the T-handle one complete rotation. Remove the tool and shield by lifting vertically from the connector. Remove the shield from the tool by rotating the socket head screw counter-clockwise three complete turns. Replacement To install a replacement shield, use the appropriate signal insertion module for the connector being repaired. The shields must be installed with the protruding stiffening ribs facing away from the backplane notch on the connector housing. See Figure5-6. Preload the shield in its proper location and then load the insertion module. Gently tap the top of the insertion module with the plastic hammer until the shield is fully seated. NOTCHES IN CONNECTOR HOUSING 5/16”T-HANDLE WRENCH (CUSTOMER SUPPLIED 62202-2100 SHIELD REMOVAL TOOL Figure 2 Doc. No: TM-622022099 Revision: H THE BACKPLANE STIFFENER RIBS ARE FACING AWAY FROM THE NOTCH SIDE OF THE CONNECTOR Release Date: 06-23-04 Revision Date: 01-28-11 Figure 5-6 UNCONTROLLED COPY Page 24 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 5.3 GbX® Daughtercard Repair Procedure: For the removal and replacement of Signal and Power Wafer replacement. The following tools are required: Stiffener press, 2,3,4, and 5 pair 62202-2070 or 62202-2620 for 75809 series only. Press Block 62201-6250 Wafer Removal Tool 62202-2080 Plastic hammer * (Or Small arbor press) * Pallet to support P.C. board * Small arbor press (optional)* * Not supplied by Molex Stiffener Removal Before using the Stiffener Press, make sure the orientation of the tool is in the right position and the pins of the tool are facing down towards the stiffener. To remove stiffener, place the small pins in the tool into the round holes of the stiffener while locating the rib on the tool against the wafer tabs that extend through the stiffener. Then rotate the knob clockwise (CW) to push the stiffener off of the wafers. See Figure 5-7 and 5-8. Note: For longer connectors, it may be necessary to work the stiffener loose by moving the press tool from one end of the connector to the other until the stiffener can be easily removed. 62202-2070 STIFFENER PRESS ROTATE KNOB CLOCKWISE SHSS WAFER TABS STIFFENER PRESS CONNECTOR Figure 5-7 STIFFENER PINS INSERTED STIFFENER INTO THE STIFFENER WAFER TABS STIFFENER Figure 5-8 Wafer Removal First identify the GbX® wafer that needs to be replaced. NOTE: Marking the defective wafer with white correction fluid or other similar material will aid in the removal process. Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 25 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling Position the 62202-2080 Wafer Removal Tool over the defective wafer with the slotted jaws over the nubs on the end of the wafer. See Figure 5-9. While holding the tool in position over the wafer, squeeze the handles until the jaws clamp the defective wafer. While applying pressure to the handles, pull straight up until the wafer slips out of the assembly. See Figure 5-10. It may be necessary to also remove and replace adjacent wafers as they are easily damaged in the process of removal. 62202-2080 WAFER REMOVAL TOOL 62202-2080 WAFER REMOVAL TOOL WAFER PC BOARD Figure 5-10 Figure 5-9 NIBS OF THE WAFER Wafer Replacement Set a support pallet beneath the PC board to allow the pins to protrude below the board when the wafers are pressed on the board. Preload the new wafers into the plated through holes. Place the Press Block on top of the wafers and behind the tabs that hold the stiffener in place. Then gently tap the block with the plastic hammer until the wafers are seated. See Figure 5-11. A small arbor press like the one shown in Figure 5-12 can be used with the press block in place of the plastic hammer. PLASTIC HAMMER 62201-6250 PRESS BLOCK SUPPORT PALLET PC BOARD PRESS BLOCK BEHIND THE WAFER TABS Doc. No: TM-622022099 Revision: H Figure 5-12 Figure 5-11 Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 26 of 28 GbX® Backplane and Daughtercard Tooling *GbX is a Trademark of Amphenol Corp. Power Module Replacement Replacing a Power Module is similar to the one described for replacing a wafer. To install a new power connector, set a support pallet beneath the PC board. This allows the pins to protrude below the board when the connector is pressed on the board. Preload the new power module into the plated through holes. Place the press block on top of the power module behind the tabs that hold the stiffener in place. Then gently tap the block with the plastic hammer until the module is seated. Stiffener Replacement Place the stiffener back on the connector and align the slots with the tabs on the wafers. See Figure 5-13. Rotate the Stiffener Press 180° so that the pins are on the top of the press and away from the stiffener. Use the jaws to push the stiffener securely in place. See Figure 5-14. Rotate the knob on the press counter clockwise (CCW). Check that the stiffener locating features are protruding through the slots in the back of the stiffener. Note: For longer connectors, move the clamp from one end of the connector to the other until the stiffener is fully seated. ROTATE KNOB COUNTER CLOCKWISE STIFFENER PRESS STIFFENER PRESS PINS FACING UP WAFER TABS STIFFENER SLOTS WAFER TABS Figure 5-13 Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 STIFFENER UNCONTROLLED COPY Figure 5-14 Page 27 of 28 *GbX is a Trademark of Amphenol Corp. GbX® Backplane and Daughtercard Tooling 5.4 Glossary of Terms: Backup (or support) Pallet Compliant Pin Connector Flat Platen Press PC Board Upper Tooling A simple fixture used to locate and support a printed circuit while a compliant pin connector is being pressed into the pc board. Considerable force is required to press one of these connectors into a pc board, thus the pc board must be adequately supported to avoid being damaged. It must have adequate clearance for the terminals when they protrude through the pc board. A connector which has terminals that are designed to give slightly when pressed into a hole in a pc board so that the terminal (pin) makes solid electrical contact with the printed circuit board, alleviating the need for soldering. A press in which the upper tooling or die set is not attached to the press ram. The ram has a simple flat plate (or platen) attached to it. For this application, the upper tooling is positioned in the connector(s). The press ram comes down on top this tooling and presses on it. When the press ram goes back up, the upper tooling stays with the connector. Abbreviation for printed circuit board The tooling that goes on top of the connector. It contains the mounting block and dies (or tools) necessary to properly apply pressure where required to push the connector terminals and locking posts into the holes in the printed circuit board. Americas Headquarters Lisle, Illinois 60532 U.S.A. 1-800-78MOLEX [email protected] Far East North Headquarters Yamato, Kanagawa, Japan 81-462-65-2324 [email protected] Far East South Headquarters Jurong, Singapore 65-6-268-6868 [email protected] European Headquarters Munich, Germany 49-89-413092-0 [email protected] Corporate Headquarters 2222 Wellington Ct. Lisle, IL 60532 U.S.A. 630-969-4550 Fax: 630-969-1352 Visit our Web site at http://www.molex.com Doc. No: TM-622022099 Revision: H Release Date: 06-23-04 Revision Date: 01-28-11 UNCONTROLLED COPY Page 28 of 28