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i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 1 of 27 revision: d revision date: 04-15-10 i-trac? backplane and daughtercard installation and repair tooling operation manual description operation maintenance
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 2 of 27 revision: d revision date: 04-15-10 warning never operate, service, install, or adjust tooling withou t proper instruction and without first reading and understan ding 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/product/itrac.html
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 3 of 27 revision: d revision date: 04-15-10 table of contents section 1 general description and available presses 2 installation and operation 3 maintenance, spare parts, perishable parts and prob lem checklist 4 available tooling 5 repair and replacement procedures
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 4 of 27 revision: d revision date: 04-15-10 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
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 5 of 27 revision: d revision date: 04-15-10 figure 1-3 press throat dimensions b a c figure 1-1 62202-3800 8-ton press general description 1.1 description this manual covers the tooling available to press molex i-trac? backplane power modules, backplane connectors, and daughtercard modules into printed circuit boards. repair tools and cust om 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 pre-seat a connector(s) by hand into the pc board. position the loading head into the connector. actuate the press to press the connector 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 holders (optional). 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 (o r flat rock) press, capable of 66n (15 lbs) of force per pin. letter description dimension (min ) (see figure1-3) a upper platen51by 102 by 25.4mm (2 by 4 by 1) b opening 89mm (3.5) c throat 150mm (6)
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 6 of 27 revision: d revision date: 04-15-10 section 2 installation and operation 2.1 printed circuit board support 2.2 press stroke adjustment 2.3 installation 2.4 operation
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 7 of 27 revision: d revision date: 04-15-10 figure 2-1 maximum clearance when connector fully seated 0.10mm (.004 in.) max. 2 installation and operation 2.1 printed circuit board support the i-trac? tooling requires up to 4 lb. per pin of force to press the connectors into the printed cir cuit boards. therefore, a backup or support is suggested to prev ent damage to the printed circuit board. the suppo rt fixture should have clearance for the connector terminals w hen they protrude through the underside of the printed circu it board. it is also recommended that the support fix ture have locating pins. due to the custom nature of each application, molex does not supply support and loca ting fixtures. the customer normally supplies thes e to fit their individual needs. the following is one simple way of making a printed circuit board support and locating fixture: 1. locate a suitable piece of material for the back up. it should be approximately 3/4 inch thick and same size or a little larger than the printed circuit board to b e used. while aluminum could be used, a rigid nonc onductive material such as a phenolic is preferred. (a stack of scrap printed circuit boards of suitable size c ould be fastened together and used.) 2. obtain a scrap printed circuit board like the on es to be assembled. attach this board to the mater ial 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 n ot bottom out when inserted (at least 5.0mm (0.20) deep). 4. locate two (2) holes on the printed circuit boar d to use as locating points. drill for and mount s uitably sized dowel pins in these two locations on the support fi xture. 5. clear out the support for any components mounted on the underside of the printed circuit board. 6 place a printed circuit board on top of the suppo rt, located by the two pins, and check that the hol es for the connector pins are aligned. 7. pre-insert a connector in the printed circuit bo ard in the correct position. 8. insert the press-in tool of proper size into the connector. 9. place the support with the printed circuit board under the press ram. 10. press the connector into the printed circuit board and observe for any deflection of the board when th e ram is at the bottom of its stroke. 2.2 press stroke adjustment most presses have some means of adjusting the strok e, please refer to the appropriate manual (for the press being used) for p ress stroke adjustments. the stroke should be adjusted so that when the pres s ram stops in the down position, the bottom of the connector is flush to 0.10mm (.004) above the surface of the printed circuit board. see figu re 2-1. 2.3 installation the only installation required is when you need to install insertion modules into a tooling holder. t o do this, use the following procedure:
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 8 of 27 revision: d revision date: 04-15-10 figure 2-2 tooling holder m3 set screw keyway figure 2-3 mounting insert module in a mounting block typical insertion modules holder figure 2-6 connector assembly on pc board support pallet support pallet locating pin locating pin pc board connector assembly figure 2-5 aligning terminal pins to holes 1. along the lower edge of the tooling holder is a row of m3 set screws, (see figure 2-2), loosen these a few turns so that they do not protrude into the inside of the holder. 2. slide the insertion modules into the tooling holder in the proper order. see figure 2-3. the modules are keyed so t hat they cannot be put in backwards. 3. now tighten the m3 set screws against the module s with two (2) set screws evenly spaced on a 10mm header insertion module and at least three (3) set screws evenly spaced on a 25 mm header insertion module. figure 2-4 shows a typical compl eted assembly. caution: do not over tighten the setscrews; this could damag e the insertion tool. note: see section 4 for details on selecting modules and press-in tools combinations. 2.4 operation backplane signal module insertion tooling 1. carefully pre-seat, by hand, the backplane signal m odule(s) into the printed circuit board hole patter n. make sure the connector(s) are oriented properly by conf irming the location of the #1 circuit notch with re spect to the printed circuit board layout. see figure 2-5. 2. locate the pre-loaded board into the support pallet (optional). see figure 2-6. figure 2-4 typical insertion tool assembly m3 x 8mm long set screws (3) evenly spaced
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 9 of 27 revision: d revision date: 04-15-10 with 62201-95xx holder figure 2-8 alone figure 2-9 typical daughtercard assembly on the pc board pc board signal module 3. locate the tooling assembly in the connector assemb ly, carefully checking alignment. the orientation feat ure on the tool must engage with the notch on the connecto r housing. see figure 2-7. 4. position the pre loaded support pallet under the pr ess platen. 5. cycle the press. see section 2.1 (press stroke adjustment). 6. when using the application tool and an appropriate press, seat the header assembly until there is less than 0 .10mm (.004 in) clearance between the bottom of the plast ic housing and the surface of the printed circuit boar d. 7. remove the loaded support pallet. 8. carefully remove the insertion tool assembly. remo ve the printed circuit board. daughtercard insertion tooling operation for inserting daughtercard assemblies is similar to backplanes and can be used alone or stac ked in a tool holder for larger connector assemblies. see figure 2-8. 1. locate the daughtercard connector assembly on the p rinted circuit board. 2. pre-seat the assembly into the board by hand. chec k for proper seating, without contact pins bending under the assembly after pre loading on to the printed ci rcuit board. see figure 2-9. 3. locate the printed circuit board with the connector assembly on the user supplied support pallet (opti onal). 4. position the insertion tooling on the connector ass embly. see figure 2-10.position the printed circui t board under the press platen (optional). caution : to prevent injury, never operate any press witho ut the guards in place. refer to the press manufacturers instruction manual. orientation feature figure 2-7 tooling located in the connector assembly connector housing
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 10 of 27 revision: d revision date: 04-15-10 figure 2-12 tooling holder m3 set screw vertical power module pc board vertical press-in tool with 62201-95xx holder figure 2-11 alone press-in tool power module press-in tool power module guide sufaces guide sufaces figure 2-10 locating pin support pallet connector assembly pc board press-in tool 5. if using the support fixture and an appropriate pre ss, seat the daughtercard module until there is less than 0. 10mm (.004 in) clearance between the bottom of the plast ic housing and the surface of the printed circuit boar d. 6. remove the loaded support pallet from the press. 7. remove the insertion tool. 8. carefully remove the assembled printed circuit boar d from the support pallet. vertical power module press-in tooling caution : vertical power module must be installed separatel y without any backplane or daughtercard assemblies in the combinations. depending on the number of modules to be installed and/or the press used, this tool can be used as a s tand- alone or with a group of press-in tools, mounted in a 62201-95xx holder (ordered separately). see fig ure 2-11. 1. if the tooling holder is being used, slide the inse rtion modules into the tooling holder in the proper order. the modules are keyed so that they cannot be put in bac kwards. 2. now tighten the m3 set screws against the modules u sing the following setups: one (1) set screw against modules under 10mm wide two (2) set screws evenly spaced on a 10mm wide pow er module. at least three (3) set screws evenly spaced on a 25 mm wide power module. 3. carefully pre-seat, by hand, the vertical power mod ule(s) into the printed circuit board hole pattern. see figure 2-12. make sure the module(s) are oriented properly to the printed circuit board layout. 4. line-up the press-in tool so that the guide surface s on the tool are in line with the sides of the ver tical power module. see figure 2-11.
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 11 of 27 revision: d revision date: 04-15-10 figure 2-15 0.10mm (0.004) maximum figure 2-14 right angle power module is seated alongside the daughtercard signal module. for ganged power modules, additional power module press-in-tools may be needed; see sales drawings for ganged product dimensions. pcb ref right angle power module and dcard press-in tool ref tooling holder 62201-95xx right angle power module dcard 5. using the application tool and an appropriate press , seat the vertical power module until there is les s than 0.10mm (.004 in) clearance between the bottom of th e plastic housing and the surface of the printed ci rcuit board. caution : to prevent injury, never operate any press witho ut the guards in place. refer to the press manufacturers instruction manual. right angle power module press-in tooling depending on the number of connectors to be install ed and/or the press used, this tool can be used alone or with a group of press-in tools, mounted in a 62201-95xx holder (ord ered separately). see figure 2-13 and 2-14. 1. if the tooling holder is being used, slide the pres s-in tools into the tooling holder in the proper order. the p ress-in tools are keyed so that they cannot be put in backw ards. 2. tighten the m3 set screws against the press-in tool using the following setups: one (1) set screw is used against the press-in tool under 10mm guide module. two (2) set screws evenly spaced on a 10mm wide press-in tool. at least three (3) set screws evenly spaced on a 25mm wide press-in tool. 3. carefully insert, by hand, the power module(s) into the printed circuit board hole pattern. 4. place the application tool on top of the power modu le with the back guide surface of the tool against the back of the power module. see figure 2-14. 5. using the application tool and an appropriate press , seat the power module until there is less than 0.10mm (.004 in) clearance between the bottom of the plastic housing and the surface of the printed circuit board. see figure 2 -15. caution : to prevent injury, never operate any press witho ut the guards in place. refer to the press manufacturers instruction manual. right angle power module press-in tool pcb ref figure 2-13 stand-alone right angle power module daughtercard press-in tool dcard
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 12 of 27 revision: d revision date: 04-15-10 support tool backplane header (ref) pcb vertical press-in tool ref vertical power module ref vertical power module support tool pcb vertical press-in tool ref vertical power module ref figure 2-18 (from side view) figure 2-17 connector terminal pins m4 screw holes (2) vertical power module support tooling the i-trac? vertical power module support tool is p laced directly under the printed circuit board. th is is done by placing the support tool under the power module or by moving the printed circuit board over the support tool. t he method used will depend on the customers application. the support tool can be a stand-alone tool shown in figure 2-16 or placed in a fixed position shown in figure 2-17. the support tool may be held in place with m4 socket head cap s crews (not included). be certain to orient the support tool properly unde r the printed circuit board. the slot of the support tool must b e directly below the connector terminals that push through the print ed circuit board when the power module is assembled to the board. s ee figure 2-18. pcb vertical power module support tool vertical press-in tool ref vertical power module ref figure 2-16 stand-alone
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 13 of 27 revision: d revision date: 04-15-10 pcb right angle power module support tool right angle press-in tool ref right angle power module ref figure 2-19 stand-alone right angle power module ref right angle power module support tool m4 screw holes (2) pcb right angle press-in tool ref right angle support tool pcb right angle press-in tool ref right angle power module ref figure 2-21 (from back view) figure 2-20 connector terminal pins right angle power module support tooling note : these tools are used only when installing i- trac? right angle power modules with no daughtercar d assemblies on either side, to provide printed circu it board support. see figure 2-19. the i-trac? right angle power module support tool i s placed directly under the printed circuit board. t his is done by placing the support tool under the power mo dule or by moving the printed circuit board over the sup port tool. the method used will depend on the customer s application. see figure 2-20 for example. the support tool can be a stand-alone tool shown in figure 2-19 or placed in a fixed position. the sup port tool may be held in place with m4 socket head cap screws (not included). be certain to orient the support tool properly unde r the printed circuit board. the slot of the suppo rt tool must be directly below the connector terminals that push th rough the printed circuit board when the power modu le is assembled to the board. see figure 2-21.
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 14 of 27 revision: d revision date: 04-15-10 section 3 maintenance 3.1 cleaning 3.2 lubrication 3.3 troubleshooting
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 15 of 27 revision: d revision date: 04-15-10 3.1. cleaning once a day, the support fixture should be cleaned o f dust and plating particles and other debris. com pressed air may be necessary to remove debris from the pin clea rance holes. caution: use extreme caution when using compressed air for cleaning, it can cau se debris to get lodged in the tooling or come flying out at the ope rator. use of proper safety glasses by the operator and onlookers is required. 3.2 lubrication there is no lubrication required on any of the i-tr ac? tooling. however, the presses each have their own requirements for lubrication and maintenance. the instruction manual for the specific press being use d should be referred to. molex provides a sheet for logging ro utine preventive maintenance in this section. 3.3 troubleshooting symptom cause solution press stroke set to low. 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 connector and/or tooling not properly aligned check to be sure the press platen is pressing squarely on the tooling block. connector being damaged "blades" on tooling bent or damaged replace tool.
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 16 of 27 revision: d revision date: 04-15-10 section 4 available tools 4.1 standard press-in-tools table 4-1 assembly tooling for i-trac? signal heade rs table 4-2 assembly tooling for i-trac? daughtercard receptacles table 4-3 standard tool holder for i-trac? backplan e header assembly table 4-4 field repair tooling for i-trac? backplan e and daughtercard assemblies 4.2 standard tool ordering procedure
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 17 of 27 revision: d revision date: 04-15-10 4.1 standard press-in-tools standard insertion tools all the applicable i-trac? connectors and the stand ard tooling required for each connector are located in these tables. table 4-1 assembly tooling for i-trac? backplane signal modul e (for use in standard tool holder) refer to the individual instruction sheets for more information on individual tools. product number tool description tool size (width) illustration i-trac? backplane signal module (5 row 5 column) (75985-*5**) press-in tool 62201-8613 18.5mm (0.73) i-trac? backplane signal module (5 row 6 column) (75985-*6**) press-in tool 62201-8625 22.2mm (0.87) i-trac? backplane signal module (5 row 6 column) (75985) series press-in tool 62201-8652 22.2mm (0.87) i-trac? backplane signal module (5 row 10 column) (75985-*1**) press-in tool 62201-8614 37.0mm (1.46) i-trac? backplane signal module (7 row 4 column) (76015-*4**) press-in tool 62201-8607 14.7mm (0.58) i-trac? backplane signal module (7 row 6 column) (76015-*6**) press-in tool 62201-8608 22.2mm (0.87) i-trac? backplane signal module (7 row 10 column) (76015-*1**) press-in tool 62201-8609 37.0mm (14.57) i-trac ? backplane signal module (11 row 5 column) (75705-*5**) press-in tool 62201-8601 18.5mm (0.73) i-trac? backplane signal module (11 row 6 column) (75705-*6**) press-in tool 62201-8602 22.2mm (0.87)
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 18 of 27 revision: d revision date: 04-15-10 product number tool description tool size (width) illustration i-trac? backplane signal module (11 row 8 column) (75705-*8**) press-in tool 62201-8617 29.6mm (1.17) i-trac? backplane signal module (11 row 10 column) (75705-*1**) press-in tool 62201-8603 37.0mm (1.46) i-trac? backplane signal module (15 row 8 column) (76035-*8**) press-in tool 62201-8619 29.6mm (1.17) i-trac? backplane signal module (15 row 9 column) (76035-*9**) press-in tool 62201-8620 33.3mm (1.31) i-trac? backplane signal module (15 row 10 column) (76035-*1**) press-in tool 62201-8621 37.0mm (1.46) i-trac? vertical power module (7 row) (78227 series) press-in tool 62201-8630 19.0mm (0.75) i-trac? vertical power module (11 row) (78232 series) press-in tool 62201-8631 26.0mm (1.02) i-trac? vertical power module (15 row) (78237 series) press-in tool 62201-8632 34.0mm (1.35) i-trac? vertical power module (7 row) (78227 series) support tool 62201-8633 23.0mm (0.91) i-trac? vertical power module (11 row) (78232 series) support tool 62201-8634 23.0mm (0.91) i-trac? vertical power module (15 row) (78237 series) support tool 62201-8635 23.0mm (0.91) i-trac? right-angle power module (7 row) (78226 and 78228 series) support tool 62201-8636 29.0mm (1.14)
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 19 of 27 revision: d revision date: 04-15-10 product number tool description tool size (width) illustration i-trac? right-angle power module (11 row) (78231 and 78233 series) support tool 62201-8637 29.0mm (1.14) i-trac? right-angle power module (15 row) (78236 series) support tool 62201-8638 29.0mm (1.14) table 4-2 assembly tooling for i-trac? ( daughtercard receptacles) product number tool description tool size (width) illustration i-trac? daughtercard module (5 row 6 column) (75990) series press-in tool 62201-8653 22.1mm (0.87) i-trac? daughtercard module (7 row 4 column) (76020-***4) press-in tool 62201-8610 14.9mm (0.59) i-trac? daughtercard module (7 row 6 column) (76020-***6) press-in tool 62201-8611 22.3mm (0.88) i-trac? daughtercard module (7 row 10 column) (76020-**10) press-in tool 62201-8612 36.9mm (14.53) i-trac? daughtercard module (11 row 5 column) (75710-***5) press-in tool 62201-8604 19.1mm (0.75) i-trac? daughtercard module (11 row 6 column) (75710-***6) press-in tool 62201-8605 22.3mm (0.88) i-trac? daughtercard module (11 row 8 column) (75710-***8) press-in tool 62201-8618 29.5mm (1.16) i-trac? daughtercard module (11 row 10 column) (75710-**10) press-in tool 62201-8606 36.9mm (1.45)
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 20 of 27 revision: d revision date: 04-15-10 product number tool description tool size (width) illustration i-trac? daughtercard module (5 row 5 column) (75990-***5) press-in tool 62201-8615 18.4mm (0.72) i-trac? daughtercard module (5 row 10 column) (75990-**10) press-in tool 62201-8616 36.9mm (1.45) i-trac? daughtercard module (15 row 8 column) (76040-***8) press-in tool 62201-8622 29.5mm (1.16) i-trac? daughtercard module (15 row 9 column) (76040-***9) press-in tool 62201-8623 33.2mm (1.31) i-trac? daughtercard module (15 row 10 column) (76040-**10) press-in tool 62201-8624 36.9mm (14.53) i-trac? right-angle power module (7 row) (78229,and 78230 series) press-in tool 62201-8627 15.0mm (0.59) i-trac? right-angle power module (11 row) (78234, and 78235 series) press-in tool 62201-8628 15.0mm (0.59) i-trac? right-angle power module (15 row) (78239 series) press-in tool 62201-8629 15.0mm (0.59) note: for ganged power modules additional power module pr ess-in tools may be needed, see the sales drawings for ganged product dimensions to select th e amount of press-in tools.
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 21 of 27 revision: d revision date: 04-15-10 table 4-3 standard tool holder for back plane header assembly tool description tool length illustration tool holder 62201-9501 24.0mm tool holder 62201-9502 72.0mm tool holder 62201-9503 156.0mm tool holder 62201-9504 216.0mm tool holder 62201-9509 254.0mm tool holder 62201-9511 304.8mm tool holder 62201-9512 406.4mm table 4-4 field repair tooling for i-trac? backplane and daug htercard assemblies product number tool description illustration i-trac ? backplane 75705, 75991, 76015, 76029, 76030, and 76035 series (7, 11, and 15 row) signal contact insertion tool 62100-5110 i-trac? daughtercard signal module 7 row (series 76020), 11 row (series 75710), and 15 row (series 76040) module removal tool 62202-3000 i-trac? daughtercard signal module 5 row (series 75990), 7 row (series 76020), 11 row (series 75710), and 15 row (series 76040) module removal tool 62202-3500 backplane header removal tool (75705, 76015, and 76035) series backplane header removal tool 62100-9610 i-trac ? backplane 75705, 75991, 76015, 76029, 76030, and 76035 series (7, 11, and 15 row) signal contact removal tool long nose pliers: newark 96f8903 msc 00321885
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 22 of 27 revision: d revision date: 04-15-10 4.1 standard tool ordering procedure stacking tooling all the insertion tooling listed in table 4-1 and 4 -2 can be stacked in any combination to be able to simultaneously press in a ny arrangement of stacked connectors. tooling holders are available in various lengths. figure 4-1 shows a typical setup for an 11 row by 8 column backplane signal module in a standard tool holder. ordering tooling for backplane connectors in order to insert a typical row of backplane conne ctors, it is necessary to select the individual insertion tools and then pick the appropriate tooling holder (see example). basic procedure caution : vertical power module must be installed separatel y without any backplane or daughtercard assemblies in the combinations. 1. determine the combination of signal modules to be i nserted. 2. select the proper press-in tools from table 4-1 and table 4-2. 3. table 4-1 and table 4-2 show the tool sizes. (l) w rite 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. 4. total up these lengths. 5. using the length just calculated, select the next l argest tooling holder from table 4-3. the tooling holder can be shorter than the total tooling but not by more t han 0.5 mm per side. 6. all of the tools selected above must be ordered sep arately. example to be inserted: (1) 5 row by 5 column and (1) 11 ro w by 8 column backplane signal module. 1. look at table 4-1 and find the required tools. in this case it would be a 62201-8613 and 62201-8617. 2. from table 4-1 get the lengths of these tools. (nu mbers may be rounded up) 62201-8613=18.5mm and 62201-8617=29.6mm. 3. add these values totaling of 48.1mm, round up (49.0 mm). 4. from the tooling holder list in table 4-3, pick the 72.0mm long holder, part number 62201-9502. 5. thus the order to molex should include the followin g: quantity order no. description 1 62201-8613 5 row by 5 column backplane signal mod ule press-in tool 1 62201-8617 11 row by 8 column backplane signal mo dule press-in tool 1 62201-9502 72.0mm long tooling holder ordering daughtercard tooling daughtercard connectors only come in standard modul e sizes. the daughtercard insertion modules length s are based on the module size. therefore, insertion too ls can be used individually for a connector assembl y or stacked in a tool holder for multiple connector assemblies. s elect the specific tool for your connector from tab le 4-3. figure 4-1 typical insertion tool assembly
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 23 of 27 revision: d revision date: 04-15-10 section 5 repair and replacement 5.1 backplane repair procedure 5.2 daughtercard repair procedure 5.3 glossary of terms
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 24 of 27 revision: d revision date: 04-15-10 insertion tool housing contact adjacent row replaced contact signal pcb figure 5-3 figure 5-2 contacts shoulder is flush against tool tip terminal clamp signal contact 5.1 i-trac? backplane repair procedure: for the removal and replacement of signal pair pins . the following tools are required: signal pin replacement tool 62100-5110 needle nose pliers (miniature) * tweezers * * not supplied by molex removal to remove damaged signal pins, grasp them with the needle nose pliers and pull straight up from the board. see fi gure 5-1. in some cases it may be necessary to straighten a bent pin with the tweezers to allow access with the pli ers. note: never reuse a backplane signal pin once it has be en removed. in addition, no more than three pins should be pressed into any plated through hole. re placement pins should be removed from a spare virgi n connector. replacement 1. place the replacement signal contact at the tip of the insertion tool and slide the contact so it rest s underneath the terminal clamp. see figure 5-2. 2. the signal contact will be guided using the groove located on the insertion tool and should be pushed all the way underneath the terminal clamp. 3. the signal contact is completely seated in the inse rtion tool when, the contacts shoulder is resting a gainst the insertion tool tip and can no longer be moved up. 4. make sure the signal contact is in the correct orie ntation. check the column where the repair signal contact is being replaced and compare the column to the contac t signal on the insertion tool. the two should be the same. the adjacent column is oriented in the oppos ite direction. see figure 5-3. 5. line-up the pins tip on the signal contact, with th e hole in the signal module and push the pin tip wi th the insertion tool through the housing and the printed circuit board. needle nose pliers connector signal pins figure 5-1
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 25 of 27 revision: d revision date: 04-15-10 clearance groove in position with the adjacent row of contacts housing contact positioned in the groove of the insertion tool contacts shoulder seated flush with housing back front figure 5-4 6. there is a clearance groove on the opposite side of the tool. when inserting the signal contact, make sure the adjacent row is positioned in this groove. 7. continue pushing the signal contact until the inser tion tool and terminal shoulder are seated securely to the inside housing surface. see figure 5-4. 8. pull the insertion tool straight up and remove. ch eck the final seating of the signal contact, the te rminal shoulder should be seated flush with inside surface on housing. 5.2 i-trac? daughtercard repair procedure: for the removal and replacement of signal modules. the following tools are required: module removal tool 62202-3000 pallet to support printed circuit board * small arbor press (optional)* *not supplied by molex connector removal before removing the daughtercard signal module from the printed circuit board, the rows of the module have to be determined. this is required so the removal tool j aws can be set-up correctly to match the proper daughtercard r ow series. count the number of rows on the front w afer housing. see 62202-3000 specification for set up. pcb removal tool dcard signal module figure 5-6
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 26 of 27 revision: d revision date: 04-15-10 figure 5-5 removal tool closed back jaw tool front and back jaws resting on signalmodule 15 row position front jaw tool gripping fingers 11 row position 7 row position jaw teeth inserted into slot of module module pcb 1. before removing individual modules be certain the t ool is adjusted to the correct row size. see figur e 5-5. 2. position the 62202-3000 removal tool over the defec tive module with the toothed jaw located over the mating end of the connector and the slotted jaw ove r the stiffener on the opposite end of the module. 3. while holding the tool in position over the module, squeeze the handles until the jaws clamp firmly. while applying pressure to the handles, pull straight up until the connector comes off the board. see figur e 5-6. backplane module replacement follow operation instruction from section 2.4. power module removal daughtercard power modules should be removed using pliers. clamp the pliers over the mating and stiffener side of the module and pull up. be caref ul of any adjacent signal modules while removing th e powers. power module replacement follow operation instructions from section 2.4.
i-trac? backplane and daughtercard tooling doc. no: tm-622018699 release date: 12-05-07 uncontrolled copy page 27 of 27 revision: d revision date: 04-15-10 5.3 glossary of terms: backup (or support) pallet a simple fixture used to locate and support a print ed 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, t hus the pc board must be adequately supported to avoid being damaged. it mus t have adequate clearance for the terminals when they protrude through the pc board. compliant pin connector a connector which has terminals that are designed t o 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 nee d for soldering. flat platen press a press in which the upper tooling or die set is no t attached to the press ram. the ram has a simple flat plate (or platen) attache d to it. for this application, the upper tooling is positioned in the connector(s). t he 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. pc board abbreviation for printed circuit board upper tooling the tooling that goes on top of the connector. it contains the mounting block and dies (or tools) necessary to properly apply pre ssure 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 amerinfo@molex.com far east north headquarters yamato, kanagawa, japan 81-462-65-2324 feninfo@molex.com far east south headquarters jurong, singapore 65-6-268-6868 fesinfo@molex.com european headquarters munich, germany 49-89-413092-0 eurinfo@molex.com 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

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