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