I-Trac™ Backplane and Daughtercard Tooling
I-TRAC™ BACKPLANE and DAUGHTERCARD
INSTALLATION and REPAIR TOOLING
Operation Manual
Description
Operation
Maintenance
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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I-Trac™ Backplane and Daughtercard Tooling
WARNING
NEVER
OPERATE, SERVICE, INSTALL, OR ADJUST TOOLING 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/product/itrac.html
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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I-Trac™ 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-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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I-Trac™ 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
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Revision Date: 04-15-10
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I-Trac™ Backplane and Daughtercard Tooling
General Description
1.4 Delivery Check
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 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 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.
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:
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.
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 Dimension (min)
(See Figure1-3)
A
B
C
Upper Platen51by 102 by 25.4mm
(2 by 4 by 1”)
Opening
89mm (3.5”)
Throat
150mm (6”)
A
B
C
Figure 1-3
PRESS THROAT DIMENSIONS
Figure 1-1
62202-3800 8-TON PRESS
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Revision Date: 04-15-10
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I-Trac™ Backplane and Daughtercard Tooling
Section 2
Installation and Operation
2.1
Printed Circuit Board Support
2.2
Press Stroke Adjustment
2.3
Installation
2.4
Operation
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I-Trac™ Backplane and Daughtercard Tooling
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 circuit boards.
Therefore, a backup or support is suggested to prevent damage to the printed circuit board. The support fixture
should have clearance for the connector terminals when they protrude through the underside of the printed circuit
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 these 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 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 printed circuit boards of suitable size could be
fastened together and used.)
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. 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 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. Pre-insert a connector in the printed circuit board 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 the ram is
at the bottom of its stroke.
0.10mm
(.004 in.)
Max.
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 0.10mm (.004”) above
the surface of the Printed circuit board. See Figure 2-1.
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:
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I-Trac™ Backplane and Daughtercard Tooling
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.
HOLDER
TYPICAL INSERTION
MODULES
Figure 2-3
MOUNTING INSERT MODULE IN A MOUNTING BLOCK
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.
3. Now tighten the M3 set screws against the modules with two (2)
set screws evenly spaced on a 10mm header insertion module and
at least three (3) set screws evenly spaced on a 25mm header
insertion module. Figure 2-4 shows a typical completed assembly.
CAUTION: Do not over tighten the setscrews; this could damage the
insertion tool.
M3 x 8mm LONG
SET SCREWS (3)
EVENLY SPACED
NOTE: See Section 4 for details on selecting modules and Press-In tools
combinations.
LOCATING
PIN
2.4 Operation
Figure 2-4
TYPICAL INSERTION
TOOL ASSEMBLY
PC BOARD
LOCATING PIN
Figure 2-5
ALIGNING TERMINAL
PINS TO HOLES
CONNECTOR
ASSEMBLY
Backplane Signal Module Insertion Tooling
SUPPORT PALLET
Figure 2-6
CONNECTOR ASSEMBLY
ON PC BOARD SUPPORT PALLET
1. Carefully pre-seat, 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. Locate the pre-loaded board into the support pallet (Optional). See Figure 2-6.
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I-Trac™ Backplane and Daughtercard Tooling
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
housing. See Figure 2-7.
4. Position the pre loaded support pallet under the press
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 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.
Daughtercard Insertion Tooling
CONNECTOR
HOUSING
ORIENTATION
FEATURE
Figure 2-7
TOOLING LOCATED IN THE
CONNECTOR ASSEMBLY
WITH 62201-95XX
HOLDER
ALONE
SIGNAL MODULE
PC BOARD
Figure 2-9
TYPICAL DAUGHTERCARD
ASSEMBLY ON THE PC BOARD
Figure 2-8
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-seat 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 user supplied support pallet (Optional).
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.
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I-Trac™ Backplane and Daughtercard Tooling
5. If using the support fixture and an appropriate press, seat
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.
PRESS-IN
TOOL
CONNECTOR
ASSEMBLY
LOCATING
PIN
PC BOARD
Figure 2-10
Vertical Power Module Press-In Tooling
SUPPORT PALLET
CAUTION: Vertical Power Module must be installed separately without any Backplane or DaughterCard
assemblies in the combinations.
WITH 62201-95XX
HOLDER
TOOLING
HOLDER
PRESS-IN
TOOL
PRESS-IN
TOOL
GUIDE SUFACES
M3 SET
SCREW
VERTICAL
PRESS-IN
TOOL
GUIDE SUFACES
VERTICAL
POWER
MODULE
POWER
MODULE
POWER
MODULE
PC BOARD
ALONE
Figure 2-11
Figure 2-12
Depending on the number of modules to be installed and/or the press used, this tool can be used as a standalone 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 put in 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-seat, 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.
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I-Trac™ Backplane and Daughtercard Tooling
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.
DAUGHTERCARD
PRESS-IN TOOL
Right Angle Power Module Press-In Tooling
RIGHT ANGLE
POWER MODULE
PRESS-IN TOOL
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
PCB REF
into the tooling holder in the proper order. The Press-In
Tools are keyed so that they cannot be put in backwards.
2. Tighten the M3 set screws against the Press-In Tool using
the following setups:
D’CARD
One (1) set screw is used against the Press-In Tool
RIGHT ANGLE POWER MODULE
under 10mm guide module.
Figure 2-13
Two (2) set screws evenly spaced on a 10mm wide
STAND-ALONE
Press-In Tool.
At least three (3) set screws evenly spaced on a
25mm wide Press-In Tool.
TOOLING HOLDER
3. Carefully insert, by hand, the power module(s) into the printed
62201-95XX
RIGHT ANGLE
circuit board hole pattern.
POWER MODULE and
D’CARD PRESS-IN TOOL
4. Place the application tool on top of the power module with the
REF
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.
PCB REF
0.10mm (0.004”)
Maximum
Figure 2-15
D’CARD
RIGHT ANGLE POWER MODULE
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.
CAUTION: To prevent injury, never operate any press without the guards in place. Refer to the press
manufacturer’s instruction manual.
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I-Trac™ Backplane and Daughtercard Tooling
Vertical Power Module Support Tooling
The I-Trac™ Vertical Power Module Support Tool is placed directly under the printed circuit board. This is done
by placing the support tool under the power module or by moving
the printed circuit board over the support tool. The method used
VERTICAL
will depend on the customer’s 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 screws (not
included).
PRESS-IN
TOOL REF
PCB
VERTICAL
POWER
MODULE REF
Be certain to orient the support tool properly under the printed
circuit board. The slot of the support tool must be directly below
the connector terminals that push through the printed circuit board
when the Power Module is assembled to the board. See Figure
2-18.
VERTICAL
POWER
MODULE
SUPPORT
TOOL
Figure 2-16
STAND-ALONE
VERTICAL
PRESS-IN
TOOL REF
VERTICAL
PRESS-IN
TOOL REF
VERTICAL
POWER MODULE
REF
VERTICAL
POWER MODULE
REF
BACKPLANE
HEADER (REF)
PCB
M4 SCREW
HOLES (2)
VERTICAL POWER
MODULE
SUPPORT TOOL
Figure 2-17
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PCB
CONNECTOR
TERMINAL PINS
SUPPORT TOOL
Figure 2-18
(From Side View)
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I-Trac™ Backplane and Daughtercard Tooling
Right Angle Power Module Support Tooling
NOTE: These tools are used only when installing ITrac™ Right Angle Power Modules with no Daughtercard
assemblies on either side, to provide printed circuit board
support. See Figure 2-19.
The I-Trac™ Right Angle Power Module Support Tool is
placed directly under the printed circuit board. This is
done by placing the support tool under the power module
or by moving the printed circuit board over the support
tool. The method used will depend on the customer’s
application. See Figure 2-20 for example.
RIGHT ANGLE
PRESS-IN
TOOL REF
PCB
RIGHT ANGLE
POWER
MODULE REF
RIGHT ANGLE
POWER MODULE
SUPPORT TOOL
The Support Tool can be a stand-alone tool shown in
Figure 2-19 or placed in a fixed position. The Support
Tool may be held in place with M4 socket head cap
screws (not included).
Figure 2-19
STAND-ALONE
Be certain to orient the support tool properly under the printed circuit board. The slot of the support tool must be
directly below the connector terminals that push through the printed circuit board when the Power Module is
assembled to the board. See Figure 2-21.
RIGHT ANGLE
PRESS-IN
TOOL REF
PCB
RIGHT ANGLE
POWER MODULE
REF
RIGHT ANGLE
PRESS-IN
TOOL REF
RIGHT ANGLE
POWER MODULE
REF
RIGHT ANGLE
POWER MODULE
SUPPORT TOOL
PCB
CONNECTOR
TERMINAL PINS
Figure 2-20
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M4 SCREW
HOLES (2)
Release Date: 12-05-07
Revision Date: 04-15-10
RIGHT ANGLE
SUPPORT TOOL
Figure 2-21
(From Back View)
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I-Trac™ Backplane and Daughtercard Tooling
Section 3
MAINTENANCE
3.1
Cleaning
3.2
Lubrication
3.3
Troubleshooting
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I-Trac™ 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, it can cause debris to get
lodged in the tooling or come flying 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 I-Trac™ 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 Troubleshooting
Symptom
Cause
Solution
Press stroke set to low.
Connector
being damaged
Connector and/or tooling not properly aligned
"Blades" on tooling bent or damaged
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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.
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I-Trac™ Backplane and Daughtercard Tooling
Section 4
AVAILABLE TOOLS
4.1
Standard Press-In-Tools
Table 4-1
Assembly Tooling for I-Trac™ Signal Headers
Table 4-2
Assembly Tooling for I-Trac™ Daughtercard Receptacles
Table 4-3
Standard Tool Holder for I-Trac™ Backplane Header Assembly
Table 4-4 Field Repair Tooling for I-Trac™ Backplane and Daughtercard
Assemblies
4.2
Standard Tool Ordering Procedure
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I-Trac™ Backplane and Daughtercard Tooling
4.1 Standard Press-In-Tools
Standard Insertion Tools
All the applicable I-Trac™ connectors and the standard tooling required for each connector are located in these
tables.
Table 4-1
Assembly Tooling for I-Trac™ Backplane Signal Module (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)
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”)
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Illustration
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I-Trac™ Backplane and Daughtercard Tooling
Product Number
Tool Description
Tool Size (Width)
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”)
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I-Trac™ Backplane and Daughtercard Tooling
Product Number
Tool Description
Tool Size (Width)
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”)
Illustration
Table 4-2
Assembly Tooling for I-Trac™ (Daughtercard Receptacles)
Product Number
Tool Description Tool Size (Width)
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”)
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
UNCONTROLLED COPY
Illustration
Page 19 of 27
I-Trac™ Backplane and Daughtercard Tooling
Product Number
Tool Description Tool Size (Width)
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”)
Illustration
NOTE: For ganged power modules additional power module press-in tools may be needed, see the sales
drawings for ganged product dimensions to select the amount of press-in tools.
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
UNCONTROLLED COPY
Page 20 of 27
I-Trac™ Backplane and Daughtercard Tooling
Table 4-3
Standard Tool Holder for Back Plane Header Assembly
Tool Description
Tool Length
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
Illustration
Table 4-4
Field Repair Tooling for I-Trac™ Backplane and Daughtercard Assemblies
Product Number
Tool Description
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
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
UNCONTROLLED COPY
Illustration
Page 21 of 27
I-Trac™ Backplane and Daughtercard Tooling
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 any 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
Figure 4-1
TYPICAL INSERTION
TOOL ASSEMBLY
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
CAUTION: Vertical Power Module must be installed separately without any Backplane or DaughterCard
assemblies in the combinations.
1. Determine the combination of signal modules to be inserted.
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) 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.
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.
6. All of the tools selected above must be ordered separately.
Example
To be inserted: (1) 5 row by 5 column and (1) 11 row 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. (Numbers may be rounded up) 62201-8613=18.5mm and
62201-8617=29.6mm.
3. Add these values totaling of 48.1mm, round up (49.0mm).
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 following:
Quantity
1
1
1
Order No.
62201-8613
62201-8617
62201-9502
Description
5 row by 5 column Backplane Signal Module Press-In Tool
11 row by 8 column Backplane Signal Module Press-In Tool
72.0mm Long Tooling Holder
Ordering Daughtercard Tooling
Daughtercard connectors only come in standard module sizes. The Daughtercard insertion modules lengths are
based on the module size. Therefore, insertion tools can be used individually for a connector assembly or stacked in
a tool holder for multiple connector assemblies. Select the specific tool for your connector from Table 4-3.
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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Page 22 of 27
I-Trac™ Backplane and Daughtercard Tooling
Section 5
Repair and Replacement
5.1
Backplane Repair Procedure
5.2
Daughtercard Repair Procedure
5.3
Glossary of Terms
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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Page 23 of 27
I-Trac™ Backplane and Daughtercard Tooling
5.1 I-Trac™ Backplane Repair Procedure:
For the removal and replacement of Signal Pair pins.
NEEDLE
NOSE
PLIERS
The following tools are required:
Signal Pin Replacement Tool 62100-5110
Needle nose pliers (miniature) *
Tweezers *
* Not supplied by Molex
CONNECTOR
FIGURE 5-1
Removal
To remove damaged signal pins, grasp them with the needle nose
SIGNAL PINS
pliers and pull straight up from the board. 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. In addition, no more than three pins
should be pressed into any plated through hole. Replacement pins should be removed from a spare virgin
connector.
Replacement
1. Place the replacement signal contact at the tip of the insertion tool and slide the contact so it rests underneath
the terminal clamp. See Figure 5-2.
TERMINAL
CLAMP
INSERTION
TOOL
REPLACED
CONTACT
SIGNAL
HOUSING
PCB
SIGNAL
CONTACT
CONTACTS SHOULDER IS
FLUSH AGAINST TOOL TIP
Figure 5-2
CONTACT
ADJACENT ROW
Figure 5-3
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 insertion tool when, the contacts shoulder is resting against the
insertion tool tip and can no longer be moved up.
4. Make sure the signal contact is in the correct orientation. Check the column where the repair signal contact is
being replaced and compare the column to the contact signal on the insertion tool. The two should be the
same. The adjacent column is oriented in the opposite direction. See Figure 5-3.
5. Line-up the pins tip on the signal contact, with the hole in the signal module and push the pin tip with the
insertion tool through the housing and the PRINTED CIRCUIT BOARD.
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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Page 24 of 27
I-Trac™ Backplane and Daughtercard Tooling
CONTACT POSITIONED
IN THE GROOVE OF THE
INSERTION TOOL
CLEARANCE
GROOVE IN POSITION
WITH THE
ADJACENT ROW OF
CONTACTS
CONTACTS SHOULDER
SEATED FLUSH
WITH HOUSING
HOUSING
Figure 5-4
FRONT
BACK
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 insertion 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. Check the final seating of the signal contact, the terminal
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.
REMOVAL TOOL
The following tools are required:
Module Removal Tool 62202-3000
Pallet to support Printed circuit board *
Small arbor press (optional)*
*Not supplied by Molex
PCB
Connector Removal
FIGURE 5-6
Before removing the DaughterCard Signal Module from the
D’CARD SIGNAL
printed circuit board, the rows of the module have to be
MODULE
determined. This is required so the Removal tool jaws can be
set-up correctly to match the proper DaughterCard Row Series. Count the number of rows on the Front Wafer
Housing. See 62202-3000 Specification for set up.
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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Page 25 of 27
I-Trac™ Backplane and Daughtercard Tooling
1. Before removing individual modules be certain the tool is adjusted to the correct row size. See Figure 5-5.
FRONT AND BACK
JAWS RESTING ON
SIGNALMODULE
REMOVAL TOOL
CLOSED
BACK JAW
TOOL
GRIPPING
FINGERS
FRONT
JAW TOOL
7 ROW
POSITION
15 ROW
POSITION
MODULE
PCB
Figure 5-5
11 ROW
POSITION
JAW TEETH
INSERTED INTO
SLOT OF MODULE
2. Position the 62202-3000 Removal Tool over the defective module with the toothed jaw located over the
mating end of the connector and the slotted jaw over 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 Figure 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 careful of any adjacent signal modules while removing the
powers.
Power Module Replacement
Follow operation instructions from section 2.4.
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
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Page 26 of 27
I-Trac™ Backplane and Daughtercard Tooling
5.3 Glossary of Terms:
Backup (or Support)
Pallet
Compliant Pin
Connector
Flat Platen Press
PC Board
Upper Tooling
Americas Headquarters
Lisle, Illinois 60532 U.S.A.
1-800-78MOLEX
amerinfo@molex.com
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.
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
Doc. No: TM-622018699
Revision: D
Release Date: 12-05-07
Revision Date: 04-15-10
UNCONTROLLED COPY
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