molex MOLEX, Impact Backplane, Impact DaughterCard Operation Manual
Impact™ Backplane and Daughtercard Tooling
IMPACT™ Backplane and DaughterCard
Installation and Repair Tooling
Operation Manual
Order No. 62201-8799
Description
Operation
Maintenance
Doc. No: TM-622018799 Release Date: 08-31-09 UNCONTROLLED COPY Page 1 of 35
Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Read and understand all of the instructions and safety information in this
manual before operating or servicing this tool.
Keep this manual available when using this tool.
Replacement manuals are available for download at no charge at
www.molex.com.
SAFETY ALERT SYMBOL
This symbol is used to call your attention to hazards or unsafe practices which could result in an injury or property
damage. The signal word, defined below, indicates the severity of the hazard. The message after the signal word
provides information for preventing or avoiding the hazard.
DANGER
DANGER:
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
CAUTION
CAUTION:
Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.
CAUTION may also be used to alert against unsafe practices associated with events that could lead
to personal injury.
WARNING
WARNING
Always wear proper eye protection when
Operating or servicing these tools.
Failure to wear eye protection could result
in serious eye injury from flying debris.
Never use a press without guards or
safety devices that are intended to prevent
hands from remaining in the die space.
Failure to observe this warning could result
in severe injury or death.
WARNING
WARNING
Never wear clothing or jewelery that is loose or
That Could potentially hang into the equipement
And get caught.
Failure to observe this warning could result in
Severe Injury or death.
Never install or service these tool while
connected to any electrical power source.
Disconnect power by unplugging the press
from its power source.
Failure to observe this warning could result
In severe injury or death.
WARNING
WARNING
Never operate, service, install, or adjust this
Machine without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine
manuals.
Use extreme caution when using compressed
air to clean the equipment.
The forces created by compressed air can force
debris into the tool.
Failure to observe these precautions may
result in injury or property damage.
Safety Warnings and Information
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Failure to observe this precaution may result in injury and property damage.
Tooling Technical Assistance
Molex offers tooling technical assistance for customers who may need some guidance for tooling adjustments. This support
can be obtained by calling either of the two numbers listed below and asking for the Molex Tooling Group.
Call Toll Free 1-800-786-6539 (US) 1-630-969-4550 (Global).
This assistance is limited to the operation and set-up of a customer’s Molex Tools tool. Questions with regard to Molex
connector products or how to identify the proper tooling and/ or tooling documentation should be directed to your local Molex
personnel or Customer Service Representative.
When calling for service on these tools it is recommended to have the following: a copy of the Operation Manual, the
Specific Application Specification Sheet and a person familiar with the tools should be present. The following information is
also recommended to supply:
1. Customer name
2. Customer address
3. Person to contact such as (name, title, e-mail, and telephone number)
4. Tools order number (Lease number also if applicable)
5. Serial number (Lease number also if applicable)
6. Molex Connector product order number
7. Urgency of request
8. Nature of problem
Molex Application Tooling Group
2200 Wellington Court
Lisle, IL 60532, USA
Tel: +1 (630) 969-4550
Fax:+1 (630) 505-0049
Visit our Web site at http://www.molex.com
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Table of Contents
IMPACT™ Backplane and DaughterCard ............................................................................................................................................... 1
Order No. 62201-8799 ............................................................................................................................................................................. 1
Safety Warnings and Information ............................................................................................................................................................ 2
Table of Contents .................................................................................................................................................................................... 4
Section 1 .................................................................................................................................................................................................. 5
General Description ............................................................................................................................................................................. 6
1.1 Description ............................................................................................................................................................................. 6
1.2 Features ................................................................................................................................................................................. 6
1.3 Technical Specifications ......................................................................................................................................................... 6
1.4 Delivery Check ....................................................................................................................................................................... 6
1.5 Tools ...................................................................................................................................................................................... 6
1.6 Press Requirements ............................................................................................................................................................... 6
Section 2 .................................................................................................................................................................................................. 7
Installation and Operation ................................................................................................................................................................... 7
2.1 Printed Circuit Board Support ................................................................................................................................................ 8
2.2 Press Stroke Adjustment ........................................................................................................................................................ 8
2.3 Installation .............................................................................................................................................................................. 8
2.4 Operation ............................................................................................................................................................................... 9
Section 3 ................................................................................................................................................................................................ 13
Maintenance ...................................................................................................................................................................................... 13
3.1. Cleaning ............................................................................................................................................................................... 14
3.2 Lubrication............................................................................................................................................................................ 14
3.3 Troubleshooting ................................................................................................................................................................... 14
Section 4 ................................................................................................................................................................................................ 15
Available Tools .................................................................................................................................................................................. 15
4.1 Standard Press-In-Tools ...................................................................................................................................................... 16
Table 4-1....................................................................................................................................................................................... 16
Table 4-2....................................................................................................................................................................................... 25
Table 4-3....................................................................................................................................................................................... 25
4.2 Standard Tool Ordering Procedure ...................................................................................................................................... 29
Section 5 ................................................................................................................................................................................................ 30
5.1 Impact™ Backplane Repair Procedure: ............................................................................................................................... 31
5.2 Glossary of Terms: ............................................................................................................................................................... 35
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Section 1
Press Requirements for Impact™ Connectors
1.1 Description
1.2 Features
1.3 Technical Specifications
1.4 Delivery Check
1.5 Tools
1.6 Press Requirements
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
General Description
1.1 Description
This manual covers the tooling available to press Molex
Impact™ Backplane Power Modules, Backplane
Connectors, Daughtercard and Coplanar Modules into
printed circuit boards. Repair tools and custom tools are
also covered. All insertion tooling is designed to go into
a flat platen press.
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 size of the
tooling used.
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 the optional tooling
holder.
Molex Presses
Molex does not offer a press that is suitable for this
application. The customer is encouraged to use one
of the many industry-standard presses to install the
Impact™ connectors.
1.6 Press Requirements
All Impact™ insertion tools are designed to fit in a flat platen
(or flat rock) press.
The press must have sufficient working area to accept the
size of the printed circuit board.
The press frame and base must withstand the insertion force
requirements for the Impact™ products.
Insertion Force Requirements
Backplane assemblies: 2.7kgf (6 lb.) per pin
Daughtercard assemblies: 1.8kgf (4 lb.) per pin
Power module assemblies: 6kgf (13.2 lb.) per pin
Press Operation Characteristics
The capability to detect force variations as low as 4.5kg
(10 lb.) during the press-in cycle; excessive force
measurement should stop the press-in cycle.
The rate of pressing can be regulated as low as
0.13mm (0.005 in) per second.
Press stroke control to within ±0.25mm (0.010 in.).
Total press stroke must be at least 19mm (0.75 in.).
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Installation and Operation
2.1 Printed Circuit Board Support
2.2 Press Stroke Adjustment
2.3 Installation
2.4 Operation
Section 2
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Figure 2-2
TOOLING HOLDER
M3 SET
SCREWS
KEYWAY
Figure 2-1
MAXIMUM CLEARANCE WHEN
CONNECTOR FULLY SEATED
0.10mm
(.004 in.)
Maximum
Installation and Operation
2.1 Printed Circuit Board Support
Due to the high forces required to press in compliant-pin connectors, a backup or support plate is suggested to prevent
damage to the printed circuit board. The support fixture should have clearance for the connector terminals if they
protrude through the underside of the printed circuit board. The support fixture should have some method of locating the
PCB consistently. Due to the custom nature of each application, Molex does not supply support and locating fixtures.
The customer normally fabricates the fixture to fit their application.
The following is one way of making a printed circuit board support and locating fixture:
1. Locate a suitable piece of material for the backup. It should be approximately 20mm thick and the same size or slightly
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 printed circuit boards of suitable size can also be fastened together.)
2. Obtain a scrap printed circuit 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 5.0mm (0.20”) deep).
4. Locate two (2) holes on the printed circuit board to use as locating points. 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 printed circuit board on top of the support, located by the two pins, and check that the holes for the connector
pins are aligned.
7. By hand, pre-insert a connector in the printed circuit board.
8. Load the insertion tool 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 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 press
manual 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 0.10mm (.004”) above the surface of the printed circuit board. See Figure 2-1.
2.3 Installation
To install insertion modules into a tooling holder (see Table 4-2), use the
following procedure:
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 that they cannot be installed
backwards.
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Figure 2-3
MOUNTING INSERT MODULE IN
A MOUNTING BLOCK
TYPICAL INSERTION
MODULES
TOOLING HOLDER
Figure 2-4
TYPICAL INSERTION
TOOL ASSEMBLY
M3 x 8mm LONG
SET SCREWS (3)
EVENLY SPACED
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
PC BOARD
SIGNAL MODULE
3. Tighten the M3 set screws against the modules with two (2) set screws evenly spaced on a 10mm wide insertion tool and
at least three (3) set screws evenly spaced on a 25mm wide insertion tool. Figure 2-4 shows a typical completed
assembly.
CAUTION: Do not over tighten the setscrews; this could damage the insertion tool.
NOTE: See Section 4 for details on selecting modules and Press-In tools combinations.
2.4 Operation
Backplane Insertion Tooling
1. Carefully pre-insert, by hand, the backplane signal module(s) into the printed circuit board hole pattern. Make sure the
connector(s) are oriented properly by confirming the location of the #1 circuit notch with respect to the printed circuit
board layout. See Figure 2-5.
2. Place the pre-loaded board into the support pallet (Optional). See Figure 2-6.
3. Locate the tooling assembly in the connector assembly, carefully checking alignment. The orientation keys on the tool must
engage with the groove on the connector housing. See Figure 2-7.
4. Position the pre-loaded support pallet under the press ram.
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
Figure 2-10
LOCATING PIN
SUPPORT PALLET
CONNECTOR
ASSEMBLY
PC BOARD
PRESS-IN
TOOL
WITH 62201-95XX
RAIL
Figure 2-8
ALONE
Figure 2-9
TYPICAL DAUGHTERCARD
ASSEMBLY ON THE PC BOARD
SIGNAL MODULE
PCB
ORIENTATION
KEY
Figure 2-7
TOOLING LOCATED IN THE
CONNECTOR ASSEMBLY
CONNECTOR
HOUSING
5. Cycle the insertion press.
6. Press the header assembly 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.
7. Remove the loaded support pallet.
8. Carefully remove the insertion tool assembly. Remove the printed circuit
board from the pallet.
Daughtercard Insertion Tooling
Operation for inserting daughtercard assemblies is similar to backplanes and
can be used alone or stacked in a tool holder for larger connector assemblies.
See Figure 2-8.
1. Locate the daughtercard connector assembly on the printed circuit board.
2. Pre-insert the assembly into the board by hand. Check for proper seating,
without contact pins bending under the assembly after pre loading on to the
Printed circuit board. See Figure 2-9.
3. Locate the printed circuit board with the connector assembly
on the support pallet.
4. Position the insertion tooling on the connector assembly.
See Figure 2-10.Position the printed circuit board under the
press platen (Optional).
CAUTION: To prevent injury, never operate any press
without the guards in place. Refer to the press
manufacturer’s instruction manual.
5. Press the daughtercard 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.
6. Remove the loaded support pallet from the press.
7. Remove the insertion tool.
8. Carefully remove the assembled printed circuit board from the support pallet.
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Revision: G Revision Date: 06-16-14
Impact™ Backplane and Daughtercard Tooling
WITH
62201-95XX
RAIL
Figure 2-11
ALONE
PRESS-IN
TOOL
POWER
HEADER
PRESS-IN
TOOL
POWER
HEADER
GUIDE
SURFACE
GUIDE
SURFACE
Figure 2-12
TOOLING
HOLDER
M3 SET
SCREW
VERTICAL
POWER
MODULE
PC BOARD
VERTICAL
PRESS-IN
TOOL
Vertical Power Module Press-In Tooling
CAUTION: Vertical Power Module must be installed separately 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 stand-alone or with a
group of press-in tools, mounted in a 62201-95XX holder (ordered separately). See Figure 2-11.
1. If the tooling holder is being used, slide the insertion modules into the tooling holder in the proper order. The modules are
keyed so that they cannot be installed backwards.
2. Now tighten the M3 set screws against the modules using the following setups:
One (1) set screw against modules under 10mm wide
Two (2) set screws evenly spaced on a 10mm wide power module.
At least three (3) set screws evenly spaced on a 25mm wide power module.
3. Carefully pre-insert, by hand, the vertical power module(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 surfaces on the tool are in line with the sides of the vertical power module.
See Figure 2-11.
5. Using the application tool and an appropriate press, seat the vertical 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.
CAUTION: To prevent injury, never operate any press without the guards in place. Refer to the press
manufacturer’s instruction manual.
Right Angle Power Module Press-In Tooling
Depending on the number of connectors to be installed 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 (ordered separately). See Figure 2-13 and 2-14.
1. If the tooling holder is being used, slide the Press-In Tools into the tooling holder in the proper order. The Press-In Tools
are keyed so that they cannot be installed backwards.
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.
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Revision: G Revision Date: 06-16-14
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