Pad ROLâ¢100A Series - Johnstech

Maintenance 

& Inspection 

Guide 

Pad ROL 100A Series 

PRODUCTION TEST CONTACTORS 

Your Contact For Higher Performance 

www.johnstech.com 

©2010 Johnstech International Corporation 

All rights reserved. 

1

Pad ROL100A 

Series 

About Johnstech 

Since 1992, Johnstech International Corporation, 

headquartered in Minneapolis, MN, has been a 

leading provider of interconnect solutions for 

semiconductor manufacturers who want higher 

first-pass yields and lower overall cost of test. 

Johnstech’s high performance Test Contactors are 

available in Pad, Leaded and Edge packages and 

are based on patented technology that provides 

superior electrical and mechanical performance. 

Johnstech also partners with Handler, Tester and 

Load Board manufacturers to ensure appropriate 

interfaces. With offices in the United States 

and Singapore; Field Service offices in California, 

Singapore & Taiwan; and representation in China, 

Israel, Japan, Korea, Southeast Asia (Malaysia, 

Philippines, Singapore, Thailand) and Taiwan, 

Johnstech is proud to provide worldwide service 

and support. 

(Please refer to the back cover for addresses and 

phone numbers or go to our website at www. 

johnstech.com.) 




2

Table of Contents 

Standard Product Information . . . . . . . . . . . 4 

Contactor Component Information . . . . . . . . 5 

Contactor Identification Information . . . . . . 6 

Contactor Verification Information. . . . . . . . 7 

Recommended Tools . . . . . . . . . . . . . . . . . . 8 

Cleaning and Maintenance Frequency . . . . . . 9 

Pre-Maintenance Troubleshooting . . . . .10-11 

Load Board & Contactor Inspection . . . . . . 12 

Load Board Inspection.. . . . . . . . . . . . . . . . . . . . . . 12 

Contactor Inspection .. . . . . . . . . . . . . . . . . . . . . . . 12 

Housing, Elastomer & Contact Inspection. 13 

Housing Inspection .. . . . . . . . . . . . . . . . . . . . . . . . 13 

Elastomer Inspection.. . . . . . . . . . . . . . . . . . . . . . . 13 

Contact Inspection. . . . . . . . . . . . . . . . . . . . . . . . . 13 

Oxide Buildup.. . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 

Contactor Removal & Installation ........14 

Contact & Elastomer Removal . . . . . . . . . . 15 

Contactor Cleaning . . . . . . . . . . . . . . . .16-18 

Light Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 

Ultrasonic Cleaning .. . . . . . . . . . . . . . . . . . . . . . . . 17 

Elastomer Installation . . . . . . . . . . . . . . . 19 

Contact Installation . . . . . . . . . . . . . . . . . 20 

Installation Verification . . . . . . . . . . . . . . 21 

Grounding Information . . . . . . . . . . . . .22-25 

Grounding Options . . . . . . . . . . . . . . . . . . . . . . . . . 22 

Ground Insert Removal.. . . . . . . . . . . . . . . . . . . . . . 23 

Ground Insert Installation (New RCI) .. . . . . . . . . . . . 24 

Ground Insert Installation (Flex-Fit RCI).. . . . . . . . . . 25 



For questions about anything contained in 

this Maintenance & Inspection Guide, 

contact your local Johnstech representative. 

If you are experiencing a technical problem 

or issue, fill out the online Tech Help Form at: 

www.johnstechhelp.com 

(All forms will be responded to within two business days.) 

OR contact the nearest Field Service Office. 

(Turn to the back cover for addresses/phone numbers.) 




3



Gold-Plated Fine Tip Contact 

Matte Tin Configuration 

≥ 0.50 mm Pitch 

(Contact # 153164-0001) 

Gold-Plated Full Tip Contact 

Matte Tin Configuration 

0.4mm Pitch 

(Contact # 152144-0001) 

Clear Elastomer 

Low-Force XL-2 Fine Tip 

Contact 

NiPdAu Configuration 

≥ 0.5mm pitch 

(Contact #161805-0001) 

Clear Elastomer 

Low-Force XL-2 Fine Tip Contact 

NiPdAu Configuration 

0.4mm pitch 

(Contact #161717-0001) 




4 

Standard Product Information 

Electrical Specifications 

(Measured using Gold-Plated and Low-Force XL Contact 

Configurations, shown on left, for Matte Tin and NiPdAu packages.) 

Matte Tin NiPdAu 

Electrical Length: .. . . . . . . . . . . . . . . . . 1.10 mm.. . . . . . . . 1.14mm 

Inductance: .. . . . . . . . . . . . . . . . . . Self: 0.23 nH.. . . . . . . 0.37 mm 

.. . . . . . . . . . . . . . . . Mutual: 0.14 nH.. . . . . . . . 0.15 nH 

Capacitance: . . . . . . . . . . . . . . . . .Ground: 0.16 pF......... 0.08 pF 

.. . . . . . . . . . . . . . . . Mutual: 0.05 pF.. . . . . . . . 0.03 pF 

S21 Insertion Loss (G-S-G): . . . . . . . .-1 dB@40 GHz. .. -1 dB @ 40 GHz 

S11 Return Loss (G-S-G):.. . . . . . . -20 dB@14.5 GHz. -20 dB @ 18.3 GHz 

S41 Crosstalk (G-S-S-G): .. . . . . . . . -20 dB@32 GHz. -20 dB @ 33.5 GHz 

Average Contact DC Resistance:.. . . . . . . . 50 mOhms. ......25 mOhms 

Current Carrying Capability: . . . . . . . . . . . . . . . 4 A . .......... 4 A 

Current Leakage:.. . . . . . . . . . . . . . .

Contactor Components 

Methodology 

Device Under Test 

Contact 

Inner/Front Elastomer 

Outer/Back Elastomer 

Load Board 



Note: The Green/Red 

Elastomer and Gold-Plated 

Contact (153164) for matte 

tin packages are shown in the 

illustrations throughout this 

document. For the NiPdAu 

package configuration, refer 

to page 4 for the correct 

Contact and Elastomer configuration. 

Standard Parts 

Most Johnstech Contactors 

have four standard parts 

that comprise the Contactor 

assembly: 

· Housing 

· Contacts 

· Elastomers 

· Alignment Plate* 

Contactor Components 

Double-Latch Vertically Compliant 

Manual Actuator (DL-VCMA)** 

Alignment Plate 

A Manual Actuator is available 

for short-run testing and 

characterization. 

*An Alignment Plate is included 

with the Contactor 

for all designs utilizing an 

Alignment Plate during 

automated test operation. 

All other designs include an 

Alignment Plate as part of 

the Manual Actuator assembly. 

Leadbackers and Alignment 

Plates work as matched 

sets; changing either one 

may require changing both 

components. 

Fully-Assembled Contactor 

Housing 

**A Single-Latch Vertically 

Compliant Manual Actuator 

(SL-VCMA), pictured here, is 

also offered for select Pad 

ROL100A Housing sizes. 

Acrylic Mounting Plate 




5



Identification 

Each Johnstech Contactor 

will have as much information 

as space allows. The 

identification system is designed 

to provide you with 

the technical information 

you need to identify the 

Contactor and its Design 

Data Sheet (example shown 

on the facing page). 

Contactor Identification 

Sample Contactor, Load Board Side Up 

9. Device Body 1. Manufacturer 6. Assembly 7. Device 8. Device 

Size (mm) Type Count Type 

5. Design Number 

10. Pitch (mm) 

3. Manufacturing 

Date Code 

Here is how to read the 

different data fields on the 

Contactors: 

1. JTI- identifies Johnstech 

International as 

the manufacturer 

2. Serial Number 

3. Manufacturing Date 

Code (see tables at right) 

4. Perimeter Contact Width 

(in inches) 

5. Design Number 

For Custom Orders: 

1234-YYZZ 

YY = Contactor 

Technology Code 

A1 = ROL100A 

02 = ROL200 

ZZ = Configuration 

(or design iteration) 

Number 

For SelecTest® Order: 

6XXX-8XXXXX 

6XXX = Design Number 

8XXXXX = Configuration 

Number 

6. Assembly Type 

TS: Test Socket 

MA: Manual Actuator 

7. Device perimeter pad 

count 

8. Device Type 

9. Device Body size (mm) 

10. Device Pad Pitch (mm) 

11. Part Number (will appear 

only if Contactor is 

a SelecTest® order) 




6 

Date Code Reference 

Week 

Week 

Letter Number Letter Number 

A 1 AA 27 

B 2 AB 28 

C 3 AC 29 

D 4 AD 30 

E 5 AE 31 

F 6 AF 32 

G 7 AG 33 

H 8 AH 34 

I 9 AI 35 

J 10 AJ 36 

K 11 AK 37 

L 12 AL 38 

M 13 AM 39 

N 14 AN 40 

O 15 AO 41 

P 16 AP 42 

Q 17 AQ 43 

R 18 AR 44 

S 19 AS 45 

T 20 AT 46 

U 21 AU 47 

V 22 AV 48 

W 23 AW 49 

X 24 AX 50 

Y 25 AY 51 

Z 26 AZ 52 

Date Code Examples: 

SN123456BK B = Week 2 K = 2001 

SN654321AAN AA = Week 27 N = 2004 

11. Part Number 

2. Serial Number 

4. Perimeter 

Contact Width 

Letter Year 

A 1991 

B 1992 

C 1993 

D 1994 

E 1995 

F 1996 

G 1997 

H 1998 

I 1999 

J 2000 

K 2001 

L 2002 

M 2003 

N 2004 

O 2005 

P 2006 

Q 2007 

R 2008 

S 2009 

T 2010 

U 2011 

V 2012

Contactor Configuration Verification 

Verify the Alignment Plate 

Example of Alignment Plate. 

Check the Alignment Plate Part 

Number (in red box) against the 

Part Number on the Design Data 

Sheet (shown below) to ensure it 

is the correct one. 

Example of Design Data Sheet 

Example of another Alignment 

Plate for the same Housing, 

with the opening size called out. 

Check the Part Number (in red 

box) against Design Data Sheet 

(below) to ensure it is correct. 



Design Data Sheet 

The Design Data Sheet contains 

Contactor Specifications 

on Load Board layout, 

contact compressed height, 

Alignment Plate opening size 

and other information necessary 

for setup and troubleshooting. 

Refer to it to verify 

you are using the correct: 

· Alignment Plate (for manual 

vs. automated testing 

and for opening-to-device 

body size) 

· Contacts (refer to part 

number and thickness) 

· Elastomer Configuration 

· Load Board Layout 

Alignment Plate 

Verification 

Refer to the Design Data 

Sheet to ensure the proper 

Alignment Plate is being 

used. Different package 

vendors and Handlers require 

different Alignment 

Plates. The Design Data 

Sheet will specify which 

one is right for which application, 

as well as any 

special engraving to assist 

with identification. 

The Design Data Sheet may be a multiple-page document. Make sure 

the Part Numbers (in the red boxes) match up. 




7



Recommended Tools 

(in order at right) 

CAUTION: Avoid touching 

the Device- and Load 

Board-interface surfaces 

of the Contacts with 

metal tools. Scratches 

on these areas may 

degrade performance. 

Recommended Tools 

Screwdriver with Allen-Head Bits— for fastening the 

Contactor to the Load Board 

10X Eye Loupe— for magnified inspection of Contactor, 

Elastomers and Contacts 

Elastomer Tool— for use in Elastomer Installation as well as 

prying Alignment Plate from Contactor 

Fine-Tip Non-Metallic Tweezers— for handling Contacts and 

Elastomers 

Scalpel— for marking Elastomer lengths 

Micro Scissors— for cutting Elastomers to length 

Probe Tool— for use in Elastomer Installation 

Fiberglass Brush and Replacement Tips— recommended for 

cleaning the Contacts (If fiberglass brushes are not allowed 

on the test floor, although not optimum, nylon brushes can be 

substituted.) 

EXTRAS: 

Finger Cots— recommended to prevent contaminating Contactor 

components with skin oils 

Protective Eye wear— recommended to protect technicians 

from Test Floor/Contactor components, Compressed Air and other 

chemicals 

Johnstech’s Maintenance & Inspection Kit 

Johnstech’s Maintenance & Inspection Kit contains many of 

the tools needed for maintenance and inspection and are designed 

especially for Johnstech high performance Contactors. 

Contact your Johnstech representative for more information. 




8 

Maintenance Kit Part Numbers— 

with torque screwdriver: 706449 

without torque screwdriver: 706448

Cleaning & Maintenance Frequency 

Determining Frequency 

Due to a wide range of variables (like those listed below), 

each Test Floor must determine their optimal cleaning and 

maintenance intervals through effective use of statistical 

process control. By carefully monitoring and recording yield 

rates and following good test floor troubleshooting procedures, 

you will be able to clearly differentiate between 

interface vs. maintenance problems and an effective maintenance 

cleaning cycle can be established to match the needs of 

each Test Floor. Contact your Johnstech representative or Field 

Service for further information or help. 



Handler Design and Setup 

Handlers have a variety of test plane configurations, device 

transportation methods, plunge mechanisms and accessories. 

Each handler has its own unique attributes. Handler set-ups 

that are not optimized can increase the required maintenance 

frequency by contributing to premature Contactor and Elastomer 

wear and Oxide Build-up on the Contacts. By working 

with Johnstech and your handler supplier, you can optimize 

handler/contactor performance to minimize downtime. 

Correct Contact Compressed Height 

Incorrect contact compressed height reduces the effectiveness 

of the Contact’s self-cleaning wipe and may cause increased 

oxide build-up and/or decreased contact life and load board 

pad life. It may also adversely affect Elastomer life by creating 

tears, cuts or Compression Set (permanent deformation). See 

examples on Page 13. The contact compressed height for each 

Contactor is specified on the Design Data Sheet. 

Package and Device Plating Variations 

Variations in packages can affect your maintenance schedule. 

Different package vendors, or even different device lots, may 

have varying amounts of Mold Flash that can decrease wear on 

the Contactor and alter device placement. Also, the method 

used for plating the device can vary the rate of debris buildup, 

and therefore varying the maintenance interval. 

Contaminants 

Accumulation of contaminants on the contactor and/or load 

board (such as Oxides and Mold Flash) will contribute to continuity 

and/or parametric failures during the test process. 

General Test Floor Maintenance Activities 

The frequency of Handler maintenance procedures also affects 

Contactor cleaning. For example, how often the Handler and 

handler test areas are blown free and/or vacuumed of debris 

impacts the effectiveness of the Contactor. Contactors exposed 

to increased levels of foreign debris are likely to require 

more frequent maintenance and cleaning. 




9



If experiencing problems 

in automated 

test, first answer these 

2 questions. 

1) Does the test socket 

work when manually 

testing with the 

Manual Actuator? 

2) Do the Witness 

Marks from the Manual 

Actuator test look the 

same as those from the 

automated test? 

If the answer to both 

questions is YES, then 

your test problem is 

probably caused by 

some variable other 

than your Johnstech 

Contactor. 

If the answer to either 

question is NO, then 

read through the checklists 

on these 2 pages, 

under the problem (in 

red) that you are experiencing. 

If this application has 

run well previously 

but is now failing, 

the troubleshooting 

must determine what 

has changed. If this 

is a new application 

troubleshooting must 

examine the original 

design. 

Pre-Maintenance Troubleshooting 

This Pre-Maintenance Troubleshooting section is to 

help you determine which part of your Johnstech 

Contactor may be inspected and/or serviced to 

address a particular Test problem. This section 

doesn’t cover Test Floor, Handler, Device or any other 

variables that may be contributing to your Test problem. 

If you still experience problems after following 

the Maintenance Instructions herein, contact your 

local Johnstech Representative or fill-out our online 

Tech Help Form at www.johnstechhelp.com. 

Experiencing Yield Fall-Off? 

There are many reasons you may be experiencing yield falloff 

but it can frequently be attributed to either Parametric or 

Continuity Failures. 

Parametric Failures are typically due to increased Contact 

Resistance which can be caused by: 

· Dirty Contacts 

Inspect Contacts per instructions on Page 13. 

· Worn or Damaged Elastomers 

Inspect Elastomers per instructions on Page 13. 

· Device-Pad-to-Contact Alignment 

Inspect the Contactor Registration per instructions on Page 12. 

· Worn or Damaged Alignment Plate 

Inspect the Alignment Plate under Contactor Inspection 

instructions on Page 12. 

· Worn or Damaged Leadbacker/Nest 

Inspect the Leadbacker and Nest. 

· Oxidation/Contamination of the Load Board 

Inspect the Load Board per instructions on Page 12. 

· Excessive Load Board Pad Wear 


Continuity Failures are typically due to Open/Short Failures 

which can be caused by: 

· Excessive Loose Debris 

Inspect Contactor per instructions on Page 12. 

· Worn or Damaged Contacts 




· Worn or Damaged Alignment Plate 

Inspect the Alignment Plate opening under the Contactor 

Inspection instructions on Page 12. 



· Contamination of the Load Board 





10

Pre-Maintenance Troubleshooting 

Experiencing Device Damage or Jamming? 

There can be many reasons why you may experience Device 

Damage or Jamming. For example, incorrectly designed or 

incompatible, worn or damaged Handler/Contactor components 

may cause pad damage or device jamming. 



Device Pad Damage or Improper Wipe can happen when 

Contacts are out of alignment. Witness Marks will be offcenter 

of device pads, which can occur due to: 

· Worn or Damaged Alignment Plate Opening 

Inspect the Alignment Plate under Contactor Inspection 




· Changes in Package Singulation 

Verify that the Alignment Plate and Leadbacker are correct for the 

Device by comparing device dimensions to the Design Data Sheet. 

· Improper Overtravel Control 

Verify that Leadbacker/Nest has proper overtravel control. Refer 

to the Contactor Specifications on your Design Data Sheet for 

Compressed, Uncompressed and Overtravel Stop dimensions. 

· Worn or Damaged Housing Slots 

Inspect Housing per instructions on Page 13. 

Device Pad Damage or Improper Wipe can also occur when 

devices experience over deflection, whereby large Witness 

Marks appear. This is can be attributed to: 

· Worn or Damaged Contacts 




· Improper Elastomers or Elastomer Installation 

Verify that Elastomers are correct per the Design Data Sheet and 

make sure Installation was performed per instructions 

on Pages 18 & 20. 







· Worn or Damaged Housing Tail Stop 

Inspect the Contactor per instructions on Page 12 & 13. 

Device Jams can occur due to: 

· Device-Pad-to-Contact Alignment 

Inspect the Contactor per instructions on Page 12. 

· Worn or Damaged Alignment Plate Opening 

Inspect the Alignment Plate opening under Contactor inspection 




· Changes in Package Singulation 

Verify that the Alignment Plate and Leadbacker are correct for the 

Device by comparing device dimensions to the Design Data Sheet. 








11



Figure 1: Example of a Load 

Board Pad Pattern 

Load Board & Contactor Inspection 

Load Board Inspection 

Johnstech recommends performing a thorough inspection of 

the Load Board before initial installation of the Contactor, as 

well as when performing routine maintenance. First, however, 

verify your Load Board against the Load Board Drawing that 

was sent to you either with your Quote or Order. 

Next, check the Contact Land Pad Pattern for signs of wear 

on the Gold. See Figure 1. If Nickel is showing, make sure 

that it is not excessive. It is acceptable to utilize the Nickel 

surface during testing; however, in some RF applications, 

signal degradation will occur. Load Boards with wear that 

extends deeper than the Nickel surface, through to the Copper, 

can cause damage to the Contacts and Elastomers and should 

be replaced or repaired. 

NOTE: Excessive Load Board wear is typically caused by 

Contact deflection or excessive force on the socket Housing. 

Contactor Inspection 

Figure 2: Example of worn (vs. 

not worn on right) Alignment 

Plate Wall; needs to be replaced 

Figure 3: Example of backlit 

Alignment Plate Wear Test 

Figure 4: Examples of Tail 

Stop Wall Wear 




12 

CAUTION: Use special care during the inspection process. 

Excessive force can fracture the Housing Slots. 

Before removing Contactor from the Load Board, use a minimum 

of 10X magnification to inspect it for: 

· Damaged, missing or excessively worn Contacts 

· Debris and Mold Flash trapped in or around Contacts 

· Cracks or chipping in the Housing or Alignment Plate 

· Cracked, deformed or missing Contact Slot Walls 

· Worn Alignment Plate (ALPL) Walls — see Figure 2. 

Complete ALPL analysis is a more complex topic than can be 

fully addressed here, but the following quick check-up may be 

helpful. 

NOTE: Remove Contactor from Load Board (per instructions 

on Pages 14) to test for Alignment Plate (ALPL) 

Wear. On a backlit surface, place device into the ALPL 

opening and then push it to one corner (see Figure 3). 

Use a Feeler Gauge Stock of 0.1mm, to check the gaps on 

the opposite sides. If Feeler Gauge Stock slips in and out 

of gap easily, the ALPL may need to be replaced. 

· Worn handler Alignment Pin Holes (contact your Johnstech 

representative for Bushings to reduce Contactor wear.) 

If any of the above conditions are observed, Contactor Maintenance 

and possibly Contact/Elastomer or ALPL replacement 

is required.

Housing, Elastomer & Contact Inspection 



Housing Inspection 

In order to inspect the Housing, Elastomers and 

Contacts, the Contactor must be removed from the 

Load Board and disassembled. Refer to instructions 

on Pages 14-15. 

Pad ROL100A Series Housings have a recommended lifespan 

of 1 million insertions. Take the dismounted/disassembled 

Contactor and using a minimum of 10X magnification, inspect 

the Housing for signs Tail Stop wear. If the Tail Stop depth 

exceeds 0.05mm (see Figure 4), replace the Housing. Conversely, 

if the Contact Wipe on the Device Pad is not placed 

correctly (see Figure 5), check the Alignment Plate walls and 

opening and Tail Stop Wall for wear. If observed, replace the 

Alignment Plate. 

Elastomer Inspection 

Using 10X+ magnification, inspect Elastomers for signs of: 

· Cuts or tears · Compression Set 

· Stretched sections 

Upon inspection, if you see excessively cut or torn Elastomers 

(see Figure 6), or if the Compression Set exceeds 0.05mm (see 

Figure 7), replace Elastomers to regain optimum performance. 

Contact Inspection 

Using 10X+ magnification, inspect Contacts for signs of: 

· Worn Tips 

· Scratches or Markings 

· Oxide Buildup (See Figure 8) 

· Debris Buildup 

· Compressed/Distorted Shape 

If any of the above are observed, discard used Contacts and 

replace with new ones. 

Oxide Buildup 

The self-cleaning wipe-action of ROL technology is designed 

to greatly reduce the amount of Oxide Buildup on Contacts. 

However, some Oxide Buildup will occur if Contactors are 

unused for 2 or more days, appearing dull gray in color (see 

Figure 8). A light brushing or a few device insertions will 

typically remove the Oxide barrier and expose a shiny surface. 

Clean the Contactor after prolonged downtime or if you experience 

a decrease in yields. Refer to Cleaning Procedures on 

Pages 16-17. 

NOTE: If Contacts have significant/excessive Oxide Buildup, 

check all components in Test Cell to ensure that device 

Figure 5: Acceptable Contact 

Wipe on Pad (Matte Tin) 

Figure 6: Example of Cut Elastomer; 

needs to be replaced. 

Figure 7: Example of Compression 

Set; this Elastomer 

needs to be replaced. 

Figure 8: Example of Oxide 

Buildup on Contact Tip (photo 

is from a test on Matte Tin). 




13



Figure 9: Screw Tightening 

Pattern 

Contactor Removal and Installation 

Contactor Removal & Installation Instructions 

It is recommended that you remove your Pad 

ROL100A Series Contactor from the Load Board 

before performing any component inspection, cleaning 

and/or maintenance. 

Step 1— Remove Contactor 

Start removal of the Contactor from the Load Board by 

loosening the fasteners. While carefully lifting Contactor 

from Load Board, use a microscope to see if Contacts 

or Ground Insert are sticking to the mounting surface. If 

either is sticking, apply several drops of Isopropyl Alcohol 

through Contact Slots and allow it to soak for 2 minutes 

before lifting from Load Board. Remove the fasteners and 

once Contactor is removed, inspect it for any loose or 

missing Contacts. Mount the Contactor to the Acrylic 

mounting plate for storage. 

Step 2— Perform Maintenance & Cleaning 

Perform the maintenance and cleaning per the instructions 

contained on the following pages. 

Recommended 

Torque Values 

in.-lb. Nm 

0-80 1.0 0.11 

2-56 2.0 0.23 

4-40 5.0 0.56 

M1.4 x 0.3 0.4 0.04 

M1.6 x 0.35 0.6 0.06 

M2 x 0.40 1.3 0.15 

M2.5 x 0.45 2.5 0.28 

M3 x 0.5 4.5 0.51 

M4 x 0.7 8.0 0.90 

Step 3— Clean Load Board 

Before remounting the Contactor to the Load Board, ensure 

that no debris is present in the interface areas. If necessary, 

use compressed air and/or Isopropyl Alcohol with a clean 

lint-free cloth to carefully wipe the bottom of the Contactor 

and the surface of the Load Board clean. 

NOTE: NEVER use Acetone or other solvents. 

Step 4— Install Contactor 

Refer to the Load Board Drawing that was sent with either 

your Quote or Order for proper footprint layout. Fasten the 

Contactor to the Load Board by fitting the screws through 

the Contactor and engaging several threads. Under a 

microscope or 10X Eye Loupe, inspect the Contact tips for 

alignment. Misaligned Contacts can damage the Alignment 

Plate, Housing and Load Board. Use the Elastomer Tool to 

realign Contacts where necessary. Evenly tighten the fasteners 

in a crisscross pattern. See Figure 9. To avoid damage 

to the Contactor or threaded inserts in the Load Board, the 

Contactor Mounting Screws should be tightened, according to 

the Recommended Torque Values in the table at left. 

Step 5— Verify Contacts 

Verify that all Contacts are properly positioned. Gently actuate 

all of the Contacts with an Elastomer Tool to ensure 

proper Contact motion. 




14 

Step 6— Verify Test Set-up 

Verify the Device-to-Contactor alignment and Handler plunge 

depth, as well as the X-Y presentation.

Contact & Elastomer Removal 

Contact & Elastomer Removal Instructions 



CAUTION: Avoid putting pressure on Slot Walls and Webs 

by not resting hands or tools in these areas while working 

on the Contactor. See Figures 10 & 11. 

Step 1— Remove Inner/Front Elastomer 

A. Turn Contactor over so Load Board side faces up. 

B. Use a Tweezers to pull out the Inner/Front (green) 

Elastomer from the Contactor. See Figure 12. 

C. Inspect Elastomer to determine whether they can be 

reused or will need to be discarded. 

Step 2— Remove Contacts 

A. With Contactor still Load Board side up, use a Tweezers 

to carefully pull Contact out of Housing. See Figure 13. 

(Many people find it easiest to start at one corner and 

work your way around the Contactor, but removal order 

is unimportant.) 

B. Inspect Contacts to determine if they need to be 

discarded or can be reused. 

C If your intent is to just change out the Elastomers and 

reuse the Contacts, take extra care in the removal 

process. Do not squeeze or bend them and do not touch 

the tips, which can affect performance. 

D. Either discard worn Contacts or set aside for reassembly. 

Figure 10: 

Figure 11: 

Slot Walls 

Slot Webs 

Step 3— Remove Outer/Back Elastomer 

As in Step 1 above, use a Tweezers to pull out the Outer or 

Back (red) Elastomer. See Figure 14. Inspect for signs of 

wear per instructions on page 13 and either set aside for 

reinstallation or discard. 

Figure 12: Removal of Inner/ 

Front (green) Elastomer 

NOTE: It is recommended to just discard used Elastomers 

and assemble Contactor with new ones, but if they are in 

exceptionally good shape, they can be set aside and reinstalled. 

Blow with Compressed Air before reinstalling. 

Figure 13: Contact Removal 

→ 

Figure 14: Removal of Outer/ 

Back (red) Elastomer 




15



Figure 15: Separating Housing 

and Alignment Plate 

Contactor Cleaning 

If debris buildup is observable upon inspection of 

the Contactor or you experience a drop in yields or 

an increase in resistance, follow the Light Cleaning 

Procedure on this page. 

Note: A Fiberglass brush is always recommend best for contactor 

cleaning but if you don’t have or are not allowed to use a 

fiberglass brush, a nylon brush may be used as a substitute. 

→ 

Step 1— Remove Contactor from Load Board 

Refer to instructions on Page 14, Step 1. 

Light Cleaning Procedure 

Step 2— Remove Alignment Plate 

Use a Scalpel to gently pry apart the Housing and Alignment 

Plate, working in an even and incremental manner 

around the Housing to avoid binding. See Figure 15. 

Figure 16: Correct direction 

for Contact brushing on the 

Top Side of the Contactor 

Figure 17: Correct direction 

for Contact brushing on the 

Bottom Side of the Contactor 

Figure 18: Compressed 

Air Cleaning 




16 

Step 3— Brush the Top Side of Contactor 

A. Mount Contactor to the Acrylic Mounting Plate. 

B. Use a fiberglass (or nylon) brush to gently clean both 

the Perimeter and Ground (even if in a Ground Insert) 

Contact Tips, brushing from the outside in, toward the 

center of the Contactor. See Figure 16. 

Step 4— Brush the Bottom Side of Contactor 

A. Remove Contactor from the Acrylic Mounting Plate and 

turn over so the Load Board side is up. 

B. Use the fiberglass (or nylon) brush again to gently clean 

both the Perimeter and Ground (even if in a Ground Insert) 

Contact Bottoms. This time brush from the center 

of the Contactor outward. See Figure 17. Avoid brushing 

Elastomers. 

Step 5— Clear Debris 

Remove any loose debris from the Contactor using one or 

both of these methods: 

· Dry, clean Compressed Air (20psi or less). See Figure 18. 

· A small vacuum 

Be sure to thoroughly clear debris from every part of the 

Contactor, including the Elastomer and Contact Slots. If no 

loose debris remains, the Contactor may be reassembled 

and reinstalled. 

NOTE: If remaining debris or foreign matter is observed, 

even after performing this Light Cleaning Procedure, try 

the Thorough Cleaning Procedure on the next page. 

Step 6— Clean Handler 

Clean the Handler per the manufacturer’s recommendations. 

Step 7— Reinstall Contactor 

If no loose debris remains on the Contactor, remount it to 

the Load Board per the instructions on Page 14, Step 4.

Contactor Cleaning 

Thorough Cleaning Procedure 

If the Contactor and Alignment Plate have excessive 

debris buildup, it is strongly recommended 

to perform a thorough cleaning with an Ultrasonic 

Cleaner. Only execute this procedure in a 

well-ventilated area with an Exhaust Hood. 



CAUTION: The Ultrasonic Cleaner should have a maximum 

power of 500W and a catch basket in the tank that prevents 

the Contactor from touching settled debris 

Step 1— Prepare the Housing 

A. Remove the Contactor from the Load Board per 

instructions on Page 14, Step 1. 

B. Gently pry apart the Housing and Alignment Plate per 

instructions in Step 2 on the opposite page. 

C. Remove Ground Insert if contactor has one. Refer to 

ground insert removal instructions on page 21. 

D. If contacts and elastomers require replacement for 

either the housing or Ground Insert, remove the used 

contacts and elastomers. 

E. If the contacts and elastomers are in good condition 

they can be left in the housing during the following 

cleaning procedures. 

Figure 19: Example of Cleaning 

a Housing in an Ultrasonic 

Cleaner; note left position. 

Figure 20: Example of Rinsing 

a Housing in an Ultrasonic 

Cleaner; note right position. 

Step 2— Prepare the Bath 

Prepare a bath of heated (40-50ºC) mild acidic (7.1 > ph > 

3.0) solution. (Common distilled white vinegar is suitable.) 

Note: For less effective cleaning, diluted isopropyl alcohol 

70/30 may be substituted if necessary. 

Step 3— Perform the Cleaning 

Operate Ultrasonic Cleaner per Manufacturer’s Instructions only. 

A. Fully immerse the populated or unpopulated Housing 

Device-side down. The bath should be pre-heated and 

run for a minimum of a 30 minute cycle. See Figure 19. 

B. Also place the alignment plate and the Ground Insert 

into the bath. 

C. Remove housing, alignment plate and Ground Insert 

from the bath and sonic rise with deionized or distilled 

water for about 10 minutes. See Figure 20. 

Note: For populated contactor Housings or Populated 

Ground inserts, inspect for missing contacts before moving 

them to the rinse bath. Some Contacts may dislodge 

during the ultrasonic cleaning. Collect them and move 

them to the Rinse bath and then reinstall before drying. 

If a Sonic Cleaner is unavailable, gently brush the 

Housing with bath solution (see above), rinse in Deionized 

or distilled Water and dry Housing out completely. 




17



Step 4— Dry the Contactor 

Current leakage may occur during testing if moisture remains 

on the Contacts. To prevent this: 

A. Carefully pat the Contactor dry with a lint-free cloth. 

B. Blow the Contactor dry with heated air. See Figure 21. 

C. If necessary, place in oven for approx. 10 minutes. 

CAUTION: DO NOT use heat guns to blow Contactors dry. 

Heated air should not exceed 100ºC or be utilized for 

longer than 30 minutes. 

Figure 21: Heated Air Drying— 

a common Hair Dryer will suffice. 

Step 5— Reassemble the Contactor 

Reassemble the Contactor per instructions on Pages 18-19. 

Step 6— Reinstall Contactor 

A. Inspect Contactor one final time for any debris, damage 

or moisture. 

B. Remount Contactor to Load Board per instructions on 

Page 14, Step 4. 




18

Elastomer Installation 

Elastomer Installation Instructions 

Before beginning, use low-pressue, clean compressed 

air on contactor to blow away any debris. 

Step 1— Cut Red Outer/Back Elastomers to Length 

A. Turn Contactor Load Board side up. 

B. Lay a length of the (red) Elastomer next to the 

Outer/Back Elastomer Slot. 

C. Use a blade to mark the Elastomer (see Figure 22) at 

the correct length, which is halfway into each End Well 

(see Figure 23). Use care not to cut the 

Torlon® Housing. 

D. Use a micro-scissors to cut Elastomer straight across. 

E. Cut the remaining 3 Elastomers (for a total of 4 red) to 

this same length. 

F. Store unused Elastomer in original packaging only. 



Figure 22: Mark Elastomer at 

appropriate length 

Step 2— Install Red Outer/Back Elastomers 

NOTE: Lubricate Elastomers with Isopropyl Alcohol, 

if needed, to facilitate installation. Please use 

special care to avoid bunching, stretching or 

twisting the Elastomer. Proper Elastomer installation 

helps optimize performance. 

A. With Contactor still Load Board side up, center the red 

Elastomer over one of the Outer/Back Elastomer Slots. 

B. Using an Elastomer Tool, gently push down into place. 

See Figure 24. 

C. Repeat Outer/Back Elastomer installation for the 

remaining 3 sides. 

Step 3— Install Green Inner/Front Elastomers 

A. Cut one end of the green Elastomer straight across 

B. Insert the cut end into the end well of the Inner/Front 

Elastomer Slot. See Figure 23. 

C. Using a Tweezers, gently “pinch and tuck” Elastomer 

into the Elastomer slot. See Figure 25. 

D. Continue working towards the right “pinching and 

tucking” at each consecutive rib in sequence (See 

Figure 26) until the right end of the Elastomer is 

securely positioned just outside the end well. 

E. Cut the end of Elastomer straight across. See Figure 23. 

F. Install the remaining Inner Elastomers in the same 

manner. The Elastomers should touch at the corners. See 

Figure 23. Please note that the green Elastomers will fit 

more snugly into the Inner/Front Elastomer Slots than the 

red Elastomers did for the Outer/Back Elastomer Slots. 

NOTE: Use a delicate touch when squeezing Elastomer 

to avoid nicks and cuts. DO NOT bunch or stretch the 

Elastomers. 

NOTE: See Page 22 for Ground Insert Elastomer 

Installation instructions. 

Figure 23: Proper fit of red 

Elastomer in End Wells 

Figure 24: Use Elastomer Tool 

to push Elastomer into Outer Slot 

→ 

→ 

→ 

Figure 25: Gently “pinch and 

tuck” green Elastomer into Inner 

Elastomer Slot 

Figure 26: “Pinch and tuck” 

green Elastomer from one end 

to the other 




19



Contact Installation 

Contact Installation Instructions 

CAUTION: Avoid putting pressure on Slot Walls and Webs 

by not resting hands or tools in these areas while working 

on the Contactor. See Figures 10 & 11 on Page 15. 

Figure 27: Align above and 

between Elastomers 

Step 1— Align and Insert Contact 

A. Turn Contactor Load Board side up. 

B. Use a tweezers to dip Contact in Isopropyl Alcohol. 

(The alcohol lubricates the Contact, making insertion 

easier.) 

C. Start installation at the last Contact Slot on either the 

left or right corner. Align the Contact above the Contact 

Slot (see Figure 27) and press the Contact down 

between the gap in the Elastomers (see Figure 28). 

Step 2— Position Contact and Insert Further 

Maneuver the head of the Contact down and towards the 

center of the Contactor. See Figure 29. 

Figure 28: Insert downward 

into gap between Elastomers 

Figure 29: Gently push Contact 

head towards center of Contactor 

Step 3— Final Adjustment 

Use the Tweezers to gently push the Contact tail down onto 

the Outer (red) Elastomer until it fits snugly. See Figure 30. 

Step 4— Contact Installation Pattern 

Proceed to the opposite side from where you started to 

install the first contact (if you started at left end, 

now start at the right end and vice versa). Install 2nd 

Contact per the steps above. Next, go to the center slot to 

install the 3rd Contact and continue on going left, right and 

center until the entire side is populated. See below for example 

of installation order. Repeat this process for the remaining 

3 sides. 

Figure 30: Gently push Contact 

tail down onto red Elastomer 




20 

1 8 10 4 12 6 14 3 7 13 5 11 9 2 

Contact Insertion Order 

NOTE: It is recommended to mount the Contactor onto the 

Acrylic Mounting Plate (shown on Page 5) when not in use 

or for inspecting, storing or shipping. If the Contactor is 

stored on Acrylic Mounting Plate for over a week, loosen 

screws to avoid Compression Set on the Rear Elastomer.

Installation Verification 

It is extremely important for the Elastomer to be 

installed correctly in order to get optimum performance 

from your Pad ROL100A Series Contactor. 

Double-check your Elastomer installation by taking the Acrylic 

Mounting Plate and gently pressing it down, evenly, onto the 

Load Board side of your Pad ROL100A Contactor. A correctly 

installed Contactor should look like this picture below. 

Clear/Red Elastomers 

for NiPdAu package 

configuration shown. 

Correct/Proper Installation of Elastomers 

Red Elastomers are 

traveling too far into the 

End Wells. Please remove 

and re-install per 

instructions on Page 

18 for optimum performance. 

Green Elastomers have 

too much gap at the corner. 

See above picture 

for comparison. 

Incorrect Installation of Elastomers 

Green/Red Elastomers 

for matte tin package 

configuration shown. 




21



Figure 31: RCI Ground Insert 

(New Elastomer retention 

design) 

Grounding Solutions & Removal 

The Pad ROL100A Series offers three main 

Grounding Options: 

1] “RCI” — ROL Contacts in a Copper Insert, for 

4x4-12x12 packages 

· New Elastomer retention design - (See Figure 31) 

· Original Flex-Fit design - (See Figure 32) 

2] “CI” — a Copper Insert for 3x3 packages 

3] “RTH” — ROL Contacts in Torlon Housing 

(see Figure 33) 

In order to maintain proper operation and ensure 

a long life for your Grounding Solution, you will 

need to perform cleaning and maintenance, much 

like you need to do for the other Components of 

your Pad ROL100A Series Contactor. 

Ground Inserts 

RCI and CI ground inserts need to be removed for cleaning 

and maintenance per the instructions on Page 23. Then follow 

the Cleaning & Installation instructions on Page 23. 

Figure 32: RCI Ground Insert 

(Original Flex-Fit design) 

Ground Contact Maintenance 

Inspection, cleaning and change-out of the Ground Contacts 

& Elastomers can be performed in the same manner as the 

Perimeter Contacts and Elastomers. (However, please note 

that depending on which way the ground Contacts are oriented, 

the direction of brushing when performing the Light 

Cleaning Procedure will vary. Refer to Figures 15 & 18 on 

Page 16 for visual cues.) 

Figure 33: RTH Grounding 




22

Ground Insert Maintenance 

Ground Insert Removal Instructions 

IMPORTANT: Use finger cots when handling Ground 

Inserts to avoid contamination with skin oils, which 

can degrade performance. 



Using covered fingers and/or the Elastomer Tool, press down 

on the Ground Insert. The Insert will easily release out of 

the Housing. See Figure 34 at right. 

Ground Insert Cleaning Instructions 

Step 1— Remove Contacts & Elastomers 

Once the Ground Insert is removed from the Housing, 

follow instructions for Contact and Elastomer removal on 

Page 15. 

Figure 34: Downward push 

frees Ground Insert from 

Housing 

Step 2— Clean Ground Insert 

A. Clean the unpopulated Ground Insert with a fiberglass 

(or nylon) brush per the instructions on Page 16. 

B. Follow up with Ultrasonic Cleaning, per instructions 

on Page 17. 

C. Inspect for mushrooming or bending. If observed, 

contact Johnstech Field Service or your 

Representative. 

Step 3— Re-assemble Ground Insert 

Follow the instructions for Elastomer & Contact 

installation on Pages 19 & 20. 

Step 4— Blow with Compressed Air 

To clear away any remaining debris, blow the Insert with 

Compressed Air before reinstalling Ground Insert. Inspect 

for remaining debris. If observed, repeat cleaning process 

again. (Refer to Pages 16-17.) 




23



Elastomer retention 

grooves 

Ledges 

Ground Insert Installation 

New Elastomer Retention Ground Insert Design 

IMPORTANT: Always ensure Ground Insert is clean 

before installing and inspect used inserts for damage 

or wear. 

Step 1— Locate and Position the Ground Insert 

Under magnification locate your Ground Insert and flip the 

insert right side up and lay on a flat surface. 

Figure 35: Position the housing 

over the RCI ground insert. 

Figure 36: Insert the two blue 

retention elastomers. (cutaway 

view) 

Step 2— Installation of the Ground Insert 

With the housing right side up, place the housing over the 

insert to begin the installation. Locate the two grooves on 

the insert (one on either side) to help guide the housing 

over the insert and position the housing over the insert. 

See Figure 35. Line up the ledges from the top of the 

housing with the Elastomer grooves in the Ground Insert. 

NOTE: When the housing and insert are properly oriented, the 

housing will drop completely down flat onto the insert. The 

top of the insert will protrude slightly above the top surface 

of the housing. Do not force the insert and housing together. 

If the housing does not drop completely down onto the 

insert, the parts are not oriented properly. 

Step 3— Install Blue Retention Elastomer 

Insert the two Blue Retention Elastomers (from the top 

side) along the sides of the insert. Cut the Blue Elastomers 

to the correct length, not exceeding the channel opening. 

See Figure 36 & 37. Use the probe tool shown on page 8. 

NOTE: Retention elastomers are installed on the sides of the 

insert. 

Figure 37: Insert the two blue 

retention elastomers. (top view) 

Figure 38: Proper installation of 

Elastomers, Contacts and Insert. 

(bottom view) 




24

Ground Insert Installation 

Original Flex-Fit RCI Ground Insert 



Note: If your Contactor uses the original flex-fit RCI Ground 

Insert design, please follow these instructions. 

IMPORTANT: Always ensure Ground Insert is clean before 

installing and inspect used Inserts for damage or wear. 

Step 1— Install Blue Retention Elastomers 

A. Locate the flexible retention ribs in the Housing on 

each side of the Insert opening. Figure 39. 

B. Lay a length of the blue Retention Elastomer next to 

the Retention Elastomer Slot. Use a blade to 

mark the Elastomer at the correct length, halfway into 

each end well. Use micro-scissors to cut the Elastomer 

straight across. Cut the other Retention Elastomer 

to this same length. 

C. Position the Blue Retention Elastomer over one of the 

Retention Elastomer slots. 

D. Using an Elastomer tool, gently push the Elastomer 

down into place. Make sure the Retention Elastomer 

extends about halfway into the end well. 

E. Repeat for the other side. See Figure 40. 

Step 2— Install Ground Insert 

A. With Contactor load board side up, locate the Ground 

Insert and housing. 

B. Gently press the Ground Insert downward into the 

housing with uniform force on all sides and making sure 

the Insert remains coplanar. The Insert should easily 

press into place. See Figure 41. 

NOTE: The Flexible Retention Ribs are fragile. DO 

NOT FORCE INSERT INTO PLACE — INSERT SHOULD 

PRESS IN EASILY WITH LIGHT PRESSURE. 

Figure 39: Flexible 

Retention Ribs 

Figure 40: Blue Retention 

Elastomer 

→ 

Figure 41: Press Ground 

Insert down to install 




25

All statements, technical 

information and recommendations 

related to the Seller’s products 

are based on information believed 

to be reliable, but the accuracy 

or completeness thereof is not 

guaranteed. Before utilizing the 

product, the user shall determine 

the suitability of the product 

for its intended use. The user 

assumes all risks and liability 

whatsoever in connection with 

such use. Any statements or 

recommendations of the Seller 

which are not contained in the 

Seller’s current publications shall 

have no force or effect unless 

contained in an agreement signed 

by an authorized officer of the 

Seller. The statements contained 

herein are made in lieu of all 

warranties expressed or implied, 

including but not limited to the 

implied merchantability and 

fitness for a particular purpose 

which warranties are hereby 

expressly disclaimed. Seller shall 

not be liable to the user or any 

other person under any legal 

theory, including but not limited 

to negligence or strict liability, 

for any injury or for any direct or 

consequential damages sustained 

or incurred by reason of the use 

of any of Seller’s products or 

services that were defective. 

Worldwide Headquarters 

1210 New Brighton Boulevard 

Minneapolis, MN 55413-1641 USA 

Tel: 612.378.2020 

Fax: 612.378.2030 

E-mail: info@johnstech.com 


Regional/Field Service Office — California, USA 

2450 Scott Boulevard 

Santa Clara, CA 95050-2504 

Tel: 408.448.2020 

Fax: 408.448.2030 

www.johnstechhelp.com 

Regional/Field Service Office — Singapore 

14 Robinson Road #13-00 

Far East Finance Building 

Singapore 048545 

Tel: 65.6385.2389 

Fax: 65.6323.1839 

Field Service Office — Taiwan 

9F, No. 522-1, Jingping Road 

Jhonghe City, Taipei County 

235 Taiwan 

Tel: +886.2.2245.6413 

Fax: +886.9.5213.2202 

© Copyright 2010 Johnstech International 

Corporation Specifications subject to change. 

Specifications subject to change without notice. 

No part of this document may be reproduced 

in any form or by any means, electronic 

or mechanical, including photocopying, 

recording or by any information storage or 

retrieval system, without expressed written 

permission from Johnstech. Johnstech and 

Johnstech logo are registered trademark s 

in the USA and other countries. Johnstech 

products and components are covered by 

patents and copyrights in the USA and other 

countries. 

For questions about anything contained in this 

Maintenance & Inspection Guide, contact your local 

Johnstech representative. 

If you are experiencing a technical problem or issue, 

fill out the online Tech Help Form at: 

www.johnstechhelp.com OR 

contact the nearest Field Service Office. 

China & 

EU RoHS 

Compliant 

LIT 1420F-710 

Printed in the USA on 100% Post-Consumer Recycled Paper made utilizing Wind Power. 




26 

Your Contact For Higher Performance.

Pad ROLâ¢100A Series - Johnstech

Create successful ePaper yourself

Delete template?

Save as template?

Pad ROLâ¢100A Series - Johnstech