154 Way CMC Header Assembly PCB Insertion Fixture
154 Way PCB Insertion Tool
Operation Manual
Order No. 62203-0500
For 154 Way CMC Headers™ Series 34763
Description
Operation
Maintenance
Doc. No: TM-622030500
Revision: B
Release Date: 02-06-12
Revision Date: 02-06-12
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Page 1 of 14
154 Way CMC Header Assembly PCB Insertion Fixture
Safety Warnings and Information
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:
Indicates an imminently hazardous situation which, if not avoided, could result in death or serious injury.
DANGER
WARNING:
Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury.
WARNING
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.
CAUTION
WARNING
Always wear proper eye protection when
Operating or servicing this tool.
Failure to wear eye protection could result
in serious eye injury from flying debris.
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.
WARNING
Never operate, service, install, or adjust this
Tool without proper instruction and without
first reading and understanding the instructions
in this manual and all applicable press and/or
wire processing machine
manuals.
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
WARNING
Excessive noise levels.
Always wear proper ear protection when operating or
servicing this tool.
WARNING
Never install or service this 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
Never use this tool without guards or safety devices
That are intended to prevent hands from remaining
in the fixture.
Failure to observe this warning could result in severe
injury or death.
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154 Way CMC Header Assembly PCB Insertion Fixture
WARNING
Do not use 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.
CAUTION
Never perform any service or maintenance other than as described in this manual.
Never modify, alter or misuse the equipment
Molex specifications are valid only when used with Molex tooling.
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 tool. Questions with regard to Molex 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 this tool it is recommended to have the following: a copy of the Tooling Manual, the Specific Tooling
Specification Sheet and a person familiar with the tool should be present. The following information is also recommended to supply:
1.
2.
3.
4.
5.
6.
7.
8.
Customer name
Customer address
Person to contact such as (name, title, e-mail, and telephone number)
Order number (Lease number also if applicable)
Serial number (Lease number also if applicable)
Molex product order number
Urgency of request
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
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
Table of Contents
Contents
Operation Manual .................................................................................................................................................................................... 1
Order No. 62203-0500 ............................................................................................................................................................................. 1
Safety Warnings and Information ............................................................................................................................................................ 2
Tooling Technical Assistance .................................................................................................................................................................. 3
Table of Contents .................................................................................................................................................................................... 4
Section 1 ............................................................................................................................................................................................. 5
General Descrition .......................................................................................................................................................................... 5
1.1.
Description ......................................................................................................................................................................... 5
1.2.
Features............................................................................................................................................................................. 5
1.3.
Technical Specification ...................................................................................................................................................... 5
1.4.
Delivery Check................................................................................................................................................................... 5
1.5.
Tools .................................................................................................................................................................................. 5
1.6.
Installation.......................................................................................................................................................................... 6
1.7
Products............................................................................................................................................................................. 6
Section 2 ............................................................................................................................................................................................. 7
Set-Up and Operation ..................................................................................................................................................................... 7
2.1
Initial Setup ........................................................................................................................................................................ 7
2.2
Adjustments ....................................................................................................................................................................... 8
2.3
Press Equipment Recommendations................................................................................................................................. 8
2.4
Operation ........................................................................................................................................................................... 9
Section 3 ........................................................................................................................................................................................... 10
3.1
Cleaning........................................................................................................................................................................... 10
3.2
Lubrication ....................................................................................................................................................................... 10
3.3
Perishable Parts .............................................................................................................................................................. 10
3.4
Preventive Maintenance Chart......................................................................................................................................... 10
3.5
Troubleshooting ............................................................................................................................................................... 11
Section 4 ........................................................................................................................................................................................... 12
4.1
Parts List .......................................................................................................................................................................... 12
4.2
Assembly ......................................................................................................................................................................... 13
4.2
Assembly (Cont.) ............................................................................................................................................................. 14
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
Section 1
General Descrition
1.1. Description
The Molex 62203-0500 154 Way CMC Header Assembly PCB Insertion Fixture is used to press a PCB onto the compliant pin interface of the
CMC Header Assembly. The header assembly is loaded into a tooling nest and the PCB is placed onto the adjustable rails of fixture. Once the
PCB is aligned to compliant pins, insertion occurs with the assistance of a customer supplied press.
1.2. Features
• The 154 Way CMC Header Assembly PCB Insertion Fixture has die set action that supports upper tooling for PCB insertion and springs to
a return position after cycling.
• Designed for the insertion of PCB thicknesses that range from 1.50mm to 2.40mm.
• The header assembly is placed into a housing nest and right angle bend compliant terminals are combed to ensure pin tip position left to
right. Front TPA retainer plate ensures front to back positioning of header assembly.
• The terminal comb tooling ensures header orientation, pin tip position, and supports right angle bend terminal shoulders during the PCB
insertion to compliant pin geometry.
• The upper tooling contacts PCB during insertion cycle and supports the PCB holes during insertion.
• The housing spring plunger located in upper tooling to support housing and prevent forward rocking during the insertion cycle.
• The PCB rails support the PCB with four spring plungers for initial PCB placement, through insertion, and assist in removal after insertion.
• The PCB rail spacing is adjustable for PCB widths up to 210mm.
• Spacer plates are provided to accommodate for various PCB thicknesses thicker than 1.5mm.
1.3. Technical Specification
Dimensions
Height
Width
Depth
Weight
250mm (9.85”)
350mm (13.80”)
220mm (8.70”)
24.9kgf (55.0lbs.)
Production Rate:
This 154 Way CMC Header Assembly PCB Insertion Fixture assembles up to 40 header assembly/ PCB’s per hour depending on the
operator’s skill.
1.4. Delivery Check
Carefully remove the 154 Way CMC Header Assembly PCB Insertion Fixture and PCB rails from its shipping container. Check to see
that following items are included in this package:
Description:
62203-0500
TM-622030500
1.5.
Quantity
PCB Insertion Fixture 1
Instruction Manual
1
Tools
The following tools are recommended for setup and adjustments to the tool:
1.
2.
3.
Metric and standard hex wrench sets
6 inch Adjustable wrench
Metric Deep Socket Set
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
1.6.
Installation
Before attempting to operate the 154 Way CMC Header Assembly PCB Insertion Fixture, make sure it is in a in a well-lighted area and
ample room around the fixture to allow easy loading and operation.
1.7 Products
Order No.
Description
34763-0001 34763-0005
34763-0006 34763-0008
34763-0010 34763-0011
Header Assembly 154 Way
34763-0012 34763-0013
34763-0014 34763-0016
34763-0017
34763-0002
Header Assembly 106 Way
34763-0004
Header Assembly 101 Way
34763-0003 34763-0007
Header Assembly 53 Way
34763-0009 34763-0015
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
Section 2
Set-Up and Operation
Read the following instructions before attempting to operate this fixture.
Principal Mechanical Parts of the 154 Way CMC Header Assembly PCB Insertion Fixture.
The 154 Way CMC Header Assembly PCB Insertion Fixture has been factory set with the exception of adjustments for PCB width and
thickness more than 1.60mm. These adjustments need to be setup and are dependent on the PCB width and thickness. However, over
time there may be some adjustments needed. Follow the steps below for initial setup and adjustments.
2.1 Initial Setup
PCB Rails
The PCB rail spacing position is dependent on the width of the PCB being inserted onto the header assembly. To setup PCB rail spacing:
Figure 2-1A
Figure 2-1B
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
1.
2.
3.
4.
5.
6.
Place PCB on front shelf of housing nest base plate and center PCB to tapped hole pattern on front face. The tapped holes on each
side edge of the PCB are the selected holes for PCB rail mounting. See Figure 2-1A.
Attach the PCB rails to the selected tap holes of housing nest base plate using (2) M4x20 SHCS; but do not tighten.
Place the housing assembly into housing nest and fully seat. See Figure 2-3.
Place the PCB onto plungers of the PCB rails and onto compliant pin tips of header assembly.
Assess clearance between PCB and inside edges of PCB rails. This clearance should be approximately 2mm minimum to allow for
adequate PCB float during PCB insertion. See Figure 2-1B.
Verify all (4) plunger positions for contact to underside of PCB. Avoid plunger contact with PCB components and cut out areas.
PCB Insertion Seat Height
The PCB insertion seat height is dependent on the
thickness of the PCB being inserted onto the header
assembly. The 154 Way CMC Header Assembly PCB
Insertion Fixture has been factory set for PCB thicknesses
of 1.50mm to 1.60mm. Reference Molex sales drawing
SD-78007-012 for adequate compliant pin tip protrusion.
To adjust the PCB insertion height for thicker PCB’s:
1.
2.
3.
4.
The Insertion spacer plates (3) of 0.30mm thickness
have been provided to account for thicker PCB’s up to
2.40mm thick. These insertion spacer plates are
Figure 2-1C
attached to the back of the housing nest for storage
purposes. See Figure 2-1C.
Remove appropriate number of spacer plates from
back of housing nest to account for difference in PCB
thickness from 1.50mm.
Remove insertion stop plate from upper tooling. Stack appropriate number of spacer plates onto top of insertion stop plate and reattach
to upper tooling. Store any unused spacer plates on the back of the housing nest. See Figure 2-1C.
If no adjustments are necessary, proceed to Operation Section 2.4 and verify adequate compliant pin tip protrusion from PCB on first
sample and ongoing desired sample frequency. If adjustments are necessary, complete adjustments and assess minimum pin tip
protrusion afterwards.
2.2 Adjustments
PCB Rail Plungers
Each of the four PCB rail plungers can be installed in three different positions to accommodate
variations in PCB geometry and components. To relocate a PCB rail plunger to another position:
1. Loosen the M5 nut on plunger from the PCB rail and select a new location.
2. Place plunger in new location and tighten the M5 nut. The Plunger tip should protrude
approximately 4mm high from the rail surface. Since the plungers contact the bottom side of
PCB, no adjustments are required due to PCB thickness.
Header Housing Plunger
Figure 2-2
The Header assembly plunger has been factory installed at approximately 8mm below upper tooling surface. The purpose of the plunger is
to prevent any forward rocking of the header assembly during PCB insertion. To adjust plunger height:
1. Loosen the M10 nut on the plunger (located in hole of the top plate of fixture) using a deep metric socket. See Figure 2-1C and 2-2.
2. Rotate plunger to desired height and re-tighten the M10 nut.
3. Ensure end of plunger does not protrude higher than the top of the top plate surface, since this is the push surface for the press ram.
2.3 Press Equipment Recommendations
Many types of presses can be used with this fixture, but to assure consistent PCB insertion Molex recommends the following press
criteria for optimum results:
1.
The capability to detect force variations as low as 4.5kg (10 lb) during the press-in cycle; excessive force measurements should stop
the press-in cycle.
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
2.
3.
4.
5.
6.
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).
Minimum force output of 20KN or 4500lbf.
Total press stroke must be at least 100mm (4.0 in).
For statistical purposes, automatic collection of force and distance data.
2.4 Operation
The 154 Way CMC Header Assembly PCB Insertion Fixture is intended to be used with a suitable press. See Press Equipment
Recommendations Section 2.3.
1.
2.
3.
Place the 154 Way CMC Header Assembly PCB Insertion Fixture with ram of press centered and biased to front of top plate of
fixture.
Orient 154 Way Header Assembly in hand with compliant pin tips up and closest to operator.
Place header assembly bay openings against back stop of housing nest and slide header assembly downward to engage initial row
of right angle bend compliant terminals to comb tooling. The housing nest has center area relief for fingers during initial header
assembly loading. With two hands apply light pressure to fully seat header assembly into final position. When header assembly
reaches final position, comb tooling will support all right angle compliant terminal shoulders and TPA retainer plate will cover header
assembly TPA by approximately 5-6mm. This ensures header assembly position front to back. See Figure 2-4A.
Figure 2-4B
Figure 2-4A
4. Place PCB on plungers of PCB rails and all compliant pin tips. See Figure 2-4B.
Note: Visually verify compliant pin tips are in PCB holes to verify alignment of PCB to header assembly.
5. Cycle the press so that the upper tooling contacts the top of hard stop of the housing nest. Failure to contact the hard stop will result in
PCB insertion depth variation. See Figure 2-1C.
6. Verify the press and die set are fully up.
7. Remove the assembled PCB and header assembly by applying even upward force on the underside of PCB with fingers on each side of
the header assembly until all rows of right angle bend compliant terminals have exited the comb tooling.
Note: The operator should use gloves during operation to protect all components on PCB and header assembly from
contamination and discharge static.
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
Section 3
3.1 Cleaning
For efficient operation, this tool should be cleaned daily with a soft bristle brush to remove any debris and plating dust from the
comb tooling and housing nest area. For continuous operation this may have to be done several times throughout the day.
See Section 3.4 for recommended Preventive Maintenance Schedule.
When it is necessary to change tooling, care should be taken to remove any debris from tapped holes or mounting surfaces.
Do not use compressed air to clean the equipment.
The forces created by compressed air can force debris into the tool or fly at an operator.
Failure to observe these precautions may result in injury or property damage.
3.2 Lubrication
1.
Lubricate the die bushings with multipurpose synthetic lubricant with Teflon or an equivalent. Molex recommends Permatex multipurpose synthetic grease with Teflon No. 82329.
WARNING: Never use a penetrant such as WD40 for any lubrication on this tool.
2.
Lubricate all points shown in Figures 3-1 with the specified grease (or equivalent).
Figure 3-1
3.3 Perishable Parts
Customers are responsible for maintaining this tool. Perishable parts are those parts that come in contact with the product and will wear
out over time. Molex recommends that all customers keep at least one set of the perishable tool kit in stock at all times. This will reduce
the amount of production down time. These parts are identified in the parts list in Section 4.
3.4 Preventive Maintenance Chart
An example of a maintenance chart is shown below. Copy and use this chart to track the maintenance of your Press or use this as a
template to create your own schedule or use your company’s standard chart, if applicable.
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
Daily: Clean. See Section 3.1.
Monthly: Clean as necessary, See Section 3.1.
Lubricate sliding parts, See Section 3.2.
CHECK SHEET MONTH _________YEAR _________
Week
Daily Clean
MON
TUE
Days of the Week
WED THU FRI
SAT
Solution
SUN
1
2
3
4
Cleaning
Reapply grease
Inspect all tooling
for wear
Yes
Soft Brush Industrial
Degreaser
Yes
Replace if signs of wear.
Schedule should be adjusted up or down depending on usage. Molex recommends that a log of preventive maintenance be kept with
the press.
3.5 Troubleshooting
Symptom
Minimum
Compliant
Pin Protrusion
Not Meet
Damage to
Header Housing
or PCB
•
Cause
•
Press not cycling completely to downward position.
•
Press not completely cycling to downward position.
•
PCB too thick.
•
Too many spacer plates in upper tooling.
•
Debris in PCB Rails.
•
PCB too thick.
•
Header Assembly not fully seated in
housing nest.
•
Compliant pin(s) not in PCB holes.
•
Damaged Comb Tooling.
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
Solution
Press not able to produce necessary downward force.
See Press Equipment Recommendations Section 2.3.
Verify upper tooling is contacting hard stop of top of housing
nest back stop. See Operation Section 2.4.
PCB thickness outside of range for fixture. Features
Section 1.2.
Remove spacer(s) based on PCB thickness. See Initial
Setup Section 2.1.
See Cleaning Section 3.1.
Remove spacer plate(s) based on PCB thickness.
See Initial Setup Section 2.1.
See Operation Section 2.4
Debris in comb tooling. See Cleaning Section 3.1.
Header Assembly to PCB Alignment incorrect.
See Operation Section 2.4.
See Perishable Parts Section 3.3.
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154 Way CMC Header Assembly PCB Insertion Fixture
Section 4
4.1 Parts List
Item
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
Doc. No: TM-622030500
Revision: B
62203-0500 154 Way CMC Header Assembly PCB Insertion Fixture
Order No. Engineering No.
Description
Perishable
62203-0501
62203-0501
Housing Nest Base Plate
62203-0502
62203-0502
Pin Combing Plate Bay YZ Row 1
Perishable
62203-0503
62203-0503
Pin Combing Plate Bay YZ Row 2-3 Perishable
62203-0504
62203-0504
Pin Combing Plate Bay-YZ Row 4
Perishable
62203-0505
62203-0505
Pin Combing Plate Bay-YZ Row 5
Perishable
62203-0506
62203-0506
TPA Retainer Plate
62203-0507
62203-0507
Pin Combing Plate Bay-X Row 1
Perishable
62203-0508
62203-0508
Pin Combing Plate Bay-X Row 2-3
Perishable
62203-0509
62203-0509
Pin Combing Plate Bay-X Row 4
Perishable
62203-0510
62203-0510
Push Plate Row 1-4
62203-0511
62203-0511
Push Plate Row 5
62203-0512
62203-0512
Housing Nest Back Stop
62203-0513
62203-0513
Housing Side Guide
62203-0514
62203-0514
Upper Mounting Block
62203-0515
62203-0515
PCB Rail Upright
62203-0516
62203-0516
PCB Rail
62203-0517
62203-0517
Brace
62203-0518
62203-0518
Insertion Stop Plate
62203-0519
62203-0519
Spacer Plate
62203-0521
62203-0521
Die Top
62203-0522
62203-0522
Die Base
63600-3988
63600-3988
Spring Plunger M5
63600-3989
63600-3989
Housing Spring Plunger M10
63600-3990
63600-3990
Threaded Rod M8 by 250 Long
63600-3991
63600-3991
Guide Post Set
63700-6016
63700-6016
Compression Spring
Hardware
N/A
N/A
M3 by 6 Long SHCS
N/A
N/A
M3 by 8 Long SHCS
N/A
N/A
M4 by 12 Long SHCS
N/A
N/A
M4 by 14 Long SHCS
N/A
N/A
M4 by 20 Long SHCS
N/A
N/A
M4 by 25 Long SHCS
N/A
N/A
M6 by 25 Long SHCS
N/A
N/A
M6 by 30 Long SHCS
N/A
N/A
4mm by 10 Long Dowel
N/A
N/A
4mm by 12 Long Dowel
N/A
N/A
4mm by 18 Long Dowel
N/A
N/A
6mm by 16 Long Dowel
N/A
N/A
M5 Hex Nut
N/A
N/A
M8 Hex Nut
N/A
N/A
M10 Hex Nut
** Available from an industrial supply company such as MSC (1-800-645-7270).
Release Date: 02-10-12
Revision Date: 02-10-12
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Qty
1
2
2
2
2
1
1
1
1
1
1
1
2
1
2
2
2
1
3
1
1
4
1
2
2
2
2**
2**
6**
6**
9**
2**
2**
4**
1**
2**
3**
4**
4**
6**
1**
Page 12 of 14
154 Way CMC Header Assembly PCB Insertion Fixture
4.2 Assembly
34
(2)
24
(2)
26
(2)
See Figure 4-2
1
2
7
8
3
4
30
9
(2)
31
15
5
(2)
(4)
(2)
16 (2)
2
37
(3)
3
4
39
17
(4)
(2)
6
32
(2)
31
(4)
(2)
29
(6)
22
Figure 4-1
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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154 Way CMC Header Assembly PCB Insertion Fixture
4.2 Assembly (Cont.)
20
41
14
(2)
25
38
(2)
36
28
(2)
18
(2)
19
(3)
35
31
11
10
34
27
(2)
40
(2)
(4)
(3)
23
33
(2)
12
13
(2)
1
See Figure 4-1
25
30
(4)
(2)
38
(2)
21
Figure 4-2
40
(2)
http://www.molex.com
Doc. No: TM-622030500
Revision: B
Release Date: 02-10-12
Revision Date: 02-10-12
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