Download Maintenance & Inspection Guide - Johnstech
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PAD SERIES TEST CONTACTOR<br />
Pad ROL 200KR<br />
Kelvin-Ready<br />
<strong>Maintenance</strong><br />
& <strong>Inspection</strong><br />
<strong>Guide</strong><br />
Your Contact for Higher Performance
Pad ROL 200KR<br />
For questions about anything<br />
contained in this <strong>Maintenance</strong><br />
& <strong>Inspection</strong> <strong>Guide</strong>, contact<br />
your local <strong>Johnstech</strong><br />
representative.<br />
If you are experiencing a<br />
technical problem or issue,<br />
fill out the online Tech Help<br />
Form at:<br />
www.johnstechhelp.com<br />
(All forms will be responded<br />
to within two business days.)<br />
OR contact the nearest Field<br />
Service Office.<br />
(Turn to the back cover for<br />
addresses/phone numbers.)<br />
2<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
ABOUT JOHNSTECH<br />
Since 1992, <strong>Johnstech</strong> International Corporation, headquartered in Minneapolis,<br />
MN, has been a leading provider of interconnect solutions for semiconductor<br />
manufacturers who want higher first-pass yields and lower overall cost of test.<br />
<strong>Johnstech</strong>’s high performance Test Contactors are available in Pad, Leaded,<br />
BGA, and Edge packages and are based on patented technology that provides<br />
superior electrical and mechanical performance. <strong>Johnstech</strong> also partners<br />
with Handler, Tester and Load Board manufacturers to ensure appropriate<br />
interfaces. With offices in the United States and Singapore; Field Service offices<br />
in California, Singapore, Philippines; and representation in China, Israel, Japan,<br />
Korea, Southeast Asia (Malaysia, Philippines, Singapore, Thailand) and Taiwan,<br />
<strong>Johnstech</strong> is proud to provide worldwide service and support.<br />
(Please refer to the back cover for addresses and phone numbers or go to<br />
our website at www.johnstech.com.)<br />
TABLE OF CONTENTS<br />
Standard Product Information .......................................4<br />
Contactor Component Information ...................................5<br />
Contactor Identification Information . . . . . . . . . . . . ......................6<br />
Contactor Configuration Verification .................................7<br />
Recommended Tools ..............................................8<br />
Cleaning and <strong>Maintenance</strong> Frequency ................................9<br />
Pre-<strong>Maintenance</strong> Troubleshooting. . . . . . . . . . . . . . ...................10-11<br />
Load Board & Contactor <strong>Inspection</strong> .................................12<br />
Load Board <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12<br />
Contactor <strong>Inspection</strong> ..............................................12<br />
Housing, Elastomer & Contact <strong>Inspection</strong> ............................13<br />
Housing <strong>Inspection</strong> ...............................................13<br />
Elastomer <strong>Inspection</strong>. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13<br />
Contact <strong>Inspection</strong> ................................................13<br />
Oxide Buildup ...................................................13<br />
Contactor Removal & Installation ...................................14<br />
Contact & Elastomer Removal . . . . . . . . . . . . . . . . . ...................15-16<br />
Contactor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17-19<br />
Light Cleaning ...................................................16<br />
Thorough/Ultrasonic Cleaning . . . . . . . . . . . . . . . . . . .....................18<br />
Elastomer Installation for ROL Contacts . . . . . . .....................20<br />
Contact Install for Sense Contacts . . . . . . . . . . . . . .....................21<br />
Elastomer Installation for Sense Contacts . . . . . . . .....................22<br />
Contact Install for ROL Contacts . . . . . . . . . . . . . .....................23<br />
Installation Verification ..........................................24-25<br />
Grounding Information ..........................................26-27<br />
Grounding Solutions Information. . . . . . . . . . . . . . . . .....................26<br />
Ground Insert Removal ............................................26<br />
Ground Insert Cleaning ............................................26<br />
Ground Insert Installation ..........................................27
Pad ROL 200KR<br />
STANDARD PRODUCT INFORMATION<br />
Mechanical Specifications<br />
Force Contact<br />
(non-Kelvin)<br />
Force + Sense (Kelvin)<br />
Contact Force: 30 grams 60 grams<br />
Physical Contact Length: Force 2.63 mm 2.63 mm<br />
Physical Compressed Height: 1.40 mm 1.40 mm<br />
Contactor Life<br />
(# of insertions):<br />
Elastomers = 300,000<br />
Force Contacts = 500,000+ (matte tin)<br />
Force Contacts = 500,000+ (NiPdAu)<br />
Sense Contacts = 1,000,000<br />
Housing =2,000,000<br />
Contact Compliance: 0.20 mm 0.20 mm<br />
Contact Wipe on Pad: 0.17 mm 0.17 mm<br />
Contact Tip Coplanarity: 0.05 mm 0.05 mm<br />
Temperature: -40°C to 155°C<br />
Housing Material: Torlon ® 5030<br />
Force Contacts:<br />
Low-Force XL-2K Fine Tip<br />
Electrical Specifications<br />
Force Contact<br />
(non-Kelvin)<br />
Force + Sense (Kelvin)<br />
Electrical Length 2.00 mm 2.00 mm<br />
Inductance:<br />
Capacitance:<br />
Self: 0.47 nH<br />
Mutual: 0.10 nH<br />
Ground: 0.16 pF<br />
Mutual: 0.06 pF<br />
Self: 3.5 nH<br />
Mutual: 0.77 nH<br />
Ground: 0.85 pF<br />
Mutual: 0.25 pF<br />
S 21<br />
Insertion Loss (GSG): -1 dB @ 19.9 GHz -1dB @ 3.0 GHz<br />
S 11<br />
Return Loss (GSG): -20 dB @ 7.8 GHz -20dB @ 0.8 GHz<br />
S 41<br />
Crosstalk (GSSG): -20 dB @ 34.7 GHz -20dB @ 17.3 GHz<br />
Average CRES:<br />
Current Carrying Capability:<br />
40 mΩ Force<br />
330 mΩ Sense<br />
≥ 2.8 A Force*<br />
Pad ROL 200KR<br />
CONTACTOR COMPONENTS<br />
Methodology<br />
Sense<br />
Elastomers<br />
Force<br />
Elastomers<br />
Sense<br />
Contact<br />
Force<br />
Contact<br />
Decoupling<br />
Components<br />
Load Board<br />
Standard Parts<br />
<strong>Johnstech</strong> Contactors have five standard parts that comprise the Contactor<br />
assembly:<br />
• Housing<br />
• Contacts<br />
• Elastomers<br />
• Acrylic Mounting Plate<br />
• Alignment Plate or Hold Down Plate<br />
Contactor Components<br />
MANUAL ACTUATOR<br />
Single-Latch Vertically Compliant<br />
Manual Actuator (SL-VCMA)<br />
A Manual Actuator is available for shortrun<br />
testing and characterization and/or<br />
troubleshooting.<br />
LEADBACKER<br />
ALIGNMENT PLATE<br />
HOUSING - TOP COVER<br />
Double-Latch Vertically Compliant Manual<br />
Actuator (DL-VCMA Plus)<br />
HOUSING - BASE<br />
Fully-Assembled Contactor<br />
Alignment Plate<br />
Acrylic Mounting Plate<br />
4<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL 200KR<br />
CONTACTOR INDENTIFICATION<br />
Sample Contactor, Load Board Side Up<br />
8. Device Body 1. Manufacturer 5. Assembly 6. Device 7. Device<br />
Size (mm) Type Count Type<br />
4. Design Number<br />
9. Pitch (mm)<br />
3. Manufacturing<br />
Date Code<br />
10. Part Number<br />
2. Serial Number<br />
Identification<br />
Each <strong>Johnstech</strong> contactor will have as much information as space allows. The<br />
identification system is designed to provide you with the technical information<br />
you need to identify the contactor and its Design Data Sheet (example shown on<br />
the facing page).<br />
Here is how to read the different data fields on the Contactors:<br />
1. JTI- identifies <strong>Johnstech</strong> International as the manufacturer<br />
2. Serial Number<br />
3. Manufacturing Date Code (see tables at right)<br />
4. Design Number<br />
For Custom Orders:<br />
1234-YYZZ, YY = Contactor Technology Code (i.e. 01 = ROL100; 02 =<br />
ROL200) ZZ = Configuration (or design iteration) Number<br />
For SelecTest Orders:<br />
6XXX-8XXXXX, 6XXX = Design Number 8XXXXX = Configuration Number<br />
5. Assembly Type<br />
TS: Test Socket<br />
MA: Manual Actuator<br />
SL: Single-Latch MA<br />
DL: Double-Latch MA<br />
6. Perimeter Pad Count<br />
7. Package Type<br />
8. Body Size (mm)<br />
9. Pad Pitch (mm)<br />
10. Part Number (will appear only if Contactor is a SelecTest® order)<br />
Date Code Reference<br />
Week<br />
Year<br />
Letter Number Letter Number<br />
A 1 A 1991<br />
B 2 B 1992<br />
C 3 C 1993<br />
D 4 D 1994<br />
E 5 E 1995<br />
F 6 F 1996<br />
G 7 G 1997<br />
H 8 H 1998<br />
I 9 I 1999<br />
J 10 J 2000<br />
K 11 K 2001<br />
L 12 L 2002<br />
M 13 M 2003<br />
N 14 N 2004<br />
O 15 O 2005<br />
P 16 P 2006<br />
Q 17 Q 2007<br />
R 18 R 2008<br />
S 19 S 2009<br />
T 20 T 2010<br />
U 21 U 2011<br />
V 22 V 2012<br />
W 23 W 2013<br />
X 24 X 2014<br />
Y 25 Y 2015<br />
Z 26 Z 2016<br />
AA 27<br />
AB 28<br />
AC 29<br />
AD 30<br />
AE 31<br />
AF 32<br />
AG 33<br />
AH 34<br />
AI 35<br />
AJ 36<br />
AK 37<br />
AL 38<br />
AM 39<br />
AN 40<br />
AO 41<br />
AP 42<br />
AQ 43<br />
AR 44<br />
AS 45<br />
AT 46<br />
AU 47<br />
AV 48<br />
AW 49<br />
AX 50<br />
AY 51<br />
AZ 52<br />
Data Code<br />
Examples:<br />
SN123456BV<br />
B = Week 2<br />
V = 2012<br />
SN654321AAT<br />
AA = Week 27<br />
T = 2010<br />
5<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
5
Pad ROL 200KR<br />
Design Data Sheet<br />
The design data sheet contains<br />
contactor specifications on load<br />
board layout, handler plunge<br />
depth, alignment plate opening<br />
size and other information<br />
necessary for setup and<br />
troubleshooting. Refer to it to<br />
verify you are using the correct:<br />
• Alignment Plate (for<br />
manual vs. automated<br />
testing and opening-tobody)<br />
• Contacts (refer to part<br />
number and thickness)<br />
• Elastomer Configuration<br />
• Load Board Layout<br />
CONTACTOR CONFIGURATION VERIFICATION<br />
Verify the Alignment Plate<br />
Alignment Plate Verification<br />
Refer to the design data sheet<br />
to ensure the proper alignment<br />
plate is being used. Different<br />
package<br />
vendors and handlers require<br />
different alignment plates. The<br />
design data dheet will specify<br />
which one is right for which<br />
application, as well as any<br />
special engraving to assist with<br />
identification.<br />
Alignment Plate Part Number<br />
only. Check this number<br />
against the Part Number on<br />
the Design Data Sheet to<br />
ensure it is the correct one.<br />
Example of Design Data Sheet<br />
Alignment Plate for same<br />
Housing, but with a differentsized<br />
opening; and that opening<br />
size information.<br />
6<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL 200KR<br />
RECOMMENDED TOOLS<br />
For installing and maintaining <strong>Johnstech</strong> Contactors:<br />
• Screwdriver with Allen-Head Bits for fastening the contactor to the load board.<br />
• 10X Eye Loupe for magnified inspection of contactor, elastomers and contacts.<br />
• Elastomer Tool for use in elastomer installation as well as prying alignment plate from contactor.<br />
• Fine-Tip Non-Metallic Tweezers for handling contacts and elastomers.<br />
• Scalpel for marking elastomer lengths.<br />
• Micro Scissors for cutting elastomers to length.<br />
• Probe Tool for use in elastomer Installation.<br />
• Fiberglass Brush and Replacement Tips recommended for cleaning the contacts (If<br />
fiberglass brushes are not allowed on the test floor, although not optimum, nylon brushes can be<br />
substituted.)<br />
Extras:<br />
• Finger Cots recommended to prevent contaminating contactor components with skin oils.<br />
• Protective Eye wear recommended to protect technicians from test floor/contactor components,<br />
compressed air and other chemicals.<br />
CAUTION: Avoid touching the device and load board interface surfaces of the<br />
contacts with metal tools. Scratches on these areas may degrade performance.<br />
Recommended Tools (in order<br />
at right)<br />
<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit<br />
<strong>Johnstech</strong>’s <strong>Maintenance</strong> & <strong>Inspection</strong> Kit contains many of the tools needed<br />
for maintenance and inspection and are designed especially for <strong>Johnstech</strong> High<br />
Performance Contactors. Contact your <strong>Johnstech</strong> Representative for more<br />
information.<br />
<strong>Maintenance</strong> Kit Part Numbers:<br />
• with torque screwdriver: 706449<br />
• without torque screwdriver: 706448<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
7
Pad ROL 200KR<br />
CLEANING & MAINTENANCE FREQUENCY<br />
Determining Frequency<br />
Due to a wide range of variables (like those listed below), each test floor must<br />
determine their optimal cleaning and maintenance intervals through effective use<br />
of statistical process control. By carefully monitoring and recording yield rates<br />
and following good test floor troubleshooting procedures, you will be able to<br />
clearly differentiate between interface vs. maintenance problems and an effective<br />
maintenance cleaning cycle can be established to match the needs of each<br />
test floor. Contact your <strong>Johnstech</strong> Representative or Field Service for further<br />
information or help.<br />
Handler Design and Setup<br />
Handlers have a variety of test plane configurations, device transportation<br />
methods, plunge mechanisms and accessories. Each handler has its own unique<br />
attributes. Handler set-ups that are not optimized can increase the required<br />
maintenance frequency by contributing to premature contactor and elastomer wear<br />
and oxide build-up on the contacts. By working with <strong>Johnstech</strong> and your handler<br />
supplier, you can optimize handler performance to minimize downtime.<br />
Correct Contact Compressed Height<br />
Incorrect contact compressed height reduces the effectiveness of the contact’s selfcleaning<br />
wipe and may cause increased oxide build-up and/or decreased contact life<br />
and load board pad life. It may also adversely affect elastomer life by creating tears,<br />
cuts or compression set (permanent deformation). See examples on Page 13. The<br />
contact compressed height for each contactor is specified on the design data sheet.<br />
Package and Device Plating Variations<br />
Variations in packages can affect your maintenance schedule. Different package<br />
vendors, or even different device lots, may have varying amounts of mold flash that<br />
can increase wear on the contactor and alter device placement. Also, the method<br />
used for plating the device can vary the rate of debris build-up, therefore varying<br />
the maintenance interval.<br />
Contaminants<br />
Accumulation of contaminants (such as oxides and mold flash) will contribute to<br />
continuity failures during the test process.<br />
General Test Floor <strong>Maintenance</strong> Activities<br />
The frequency of handler maintenance procedures also affects contactor cleaning.<br />
For example, how often the handler and handler test areas are blown free of debris<br />
impacts the effectiveness of the contactor. Contactors exposed to increased levels<br />
of foreign debris are likely to require more frequent maintenance and cleaning.<br />
8<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL 200KR<br />
PRE-MAINTENANCE TROUBLESHOOTING<br />
This Pre-<strong>Maintenance</strong> Troubleshooting section is to help you determine which<br />
part of your <strong>Johnstech</strong> contactor may be inspected and/or serviced to address a<br />
particular test problem. This section doesn’t cover test floor, handler, device or any<br />
other variables that may be contributing to your test problem. If you still experience<br />
problems after following the <strong>Maintenance</strong> Instructions herein, contact your local<br />
<strong>Johnstech</strong> Representative or fill-out our online Tech Help Form at www.johnstechhelp.<br />
com/support.<br />
Experiencing Yield Fall-Off<br />
There are many reasons you may be experiencing yield fall-off but it can frequently<br />
be attributed to either parametric or continuity failures.<br />
Parametric failures are typically due to increased contact resistance which<br />
can be caused by:<br />
• Dirty Contacts: Inspect contacts per instructions on Page 13.<br />
• Worn or Damaged Elastomers: Inspect elastomers per instructions on Page 13.<br />
• Device-Pad-to-Contact Alignment: Inspect the contactor registration per instructions on Page 12.<br />
• Worn or Damaged Alignment Plate: Inspect the alignment plate under Contactor <strong>Inspection</strong><br />
instructions on Page 12.<br />
• Worn or Damaged Leadbacker/Nest: Inspect the leadbacker and nest.<br />
• Oxidation/Contamination of the Load Board: Inspect the load board per instructions on Page<br />
12.<br />
• Excessive Load Board Pad Wear: Inspect the load board per instructions on Page 12.<br />
Continuity failures are typically due to open/short failures which can be<br />
caused by:<br />
• Excessive Loose Debris: Inspect contactor per instructions on Page 12.<br />
• Worn or Damaged Contacts: Inspect contacts per instructions on Page 13.<br />
• Worn or Damaged Elastomers: Inspect elastomers per instructions on Page 13.<br />
• Worn or Damaged Alignment Plate: Inspect the alignment plate under contactor inspection<br />
instructions on Page 12.<br />
• Worn or Damaged Leadbacker/Nest: Inspect the leadbacker and nest.<br />
• Contamination of the Load Board: Inspect the load board per instructions on Page 12.<br />
If experiencing problems in<br />
automated test, first answer<br />
these 2 questions.<br />
1) Does the test socket work<br />
when manually testing with the<br />
Manual Actuator<br />
2) Do the witness marks from<br />
the Manual Actuator test look<br />
the same as those from the<br />
automated test<br />
If the answer to both questions<br />
is YES, then your test problem<br />
is probably caused by some<br />
variable other than your<br />
<strong>Johnstech</strong> Contactor.<br />
If the answer to either question<br />
is NO, then read through the<br />
checklists on these 2 pages,<br />
under the problem (in red) that<br />
you are experiencing.<br />
If this application has run well<br />
previously but is now failing,<br />
the troubleshooting must<br />
determine what has changed.<br />
If this is a new application<br />
troubleshooting must examine<br />
the original design.<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
9
Pad ROL 200KR<br />
PRE-MAINTENANCE TROUBLESHOOTING<br />
Experiencing Device Damage or Jamming<br />
There can be many reasons why you experience device damage or jamming. For<br />
example, incorrectly designed or incompatible, worn or damaged handler/contactor<br />
components may cause pad damage or device jamming.<br />
Device pad damage or improper wipe can happen when contacts are out of<br />
alignment. Witness marks will be off-center on the device pads, which can<br />
occur due to:<br />
• Worn or Damaged Alignment Plate Opening: Inspect the alignment plate under contactor<br />
<strong>Inspection</strong> Instructions on Page 12.<br />
• Worn or Damaged Leadbacker/Nest: Inspect the leadbacker and nest.<br />
• Changes in Package Singulation: Verify that the alignment plate and leadbacker are correct for<br />
the device by comparing device dimensions to the design data sheet on Page 7.<br />
• Improper Overtravel Control: Verify that leadbacker/nest has proper overtravel control. Refer<br />
to the contactor specifications on your design data sheet for compressed, uncompressed and<br />
overtravel stop measurements.<br />
• Worn or Damaged Housing Slots: Inspect housing per instructions on Page 13.<br />
Device pad damage or improper wipe can also occur when devices<br />
experience over deflection, whereby large witness marks appear. This can be<br />
attributed to:<br />
• Worn or Damaged Contacts: Inspect contacts per instructions on Page 13.<br />
• Worn or Damaged Elastomers: Inspect elastomers per instructions on Page 13.<br />
• Improper Elastomers or Elastomer Installation: Verify that elastomers are correct per your<br />
design data sheet and make sure Installation was performed per instructions on Page 20.<br />
• Worn or Damaged Leadbacker/Nest: Inspect the leadbacker and nest.<br />
• Improper Overtravel Control: Verify that leadbacker/nest has proper overtravel control. Refer<br />
to the Contactor Specifications on your design data sheet for compressed, uncompressed and<br />
overtravel stop measurements.<br />
• Worn or Damaged Housing Tail Stop: Inspect the contactor per instructions on Page 12.<br />
Device Jams can occur due to:<br />
• Device-Pad-to-Contact Alignment: Inspect the contactor registration per instructions on Page 12.<br />
• Worn or Damaged Alignment Plate Opening: Inspect the alignment plate opening under<br />
Contactor <strong>Inspection</strong> instructions on Page 12.<br />
• Worn or Damaged Leadbacker/Nest: Inspect the leadbacker and nest.<br />
• Changes in Package Singulation: Verify that the alignment plate and leadbacker are correct for<br />
the device by comparing device dimensions to the design data sheet.<br />
• Improper Overtravel Control: Verify that leadbacker/nest has proper overtravel control. Refer to<br />
the Contactor Specifications on your design data sheet for compressed, uncompressed and overtravel<br />
stop measurements.<br />
10<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.
Pad ROL 200KR<br />
LOAD BOARD & CONTACTOR INSPECTION<br />
Load Board <strong>Inspection</strong><br />
<strong>Johnstech</strong> recommends performing a thorough inspection of the load board before<br />
initial installation of the contactor, as well as when performing routine maintenance.<br />
First, however, verify your load board against the load board drawing that was sent<br />
to you either with your quote or order.<br />
Next, check the contact land pad pattern for signs of wear on the gold (see Figure<br />
1). If Nickel is showing, make sure that it is not excessive. It is acceptable to<br />
utilize the nickel surface during testing; however, in some RF applications, signal<br />
degradation will occur. Load Boards with wear that extends deeper than the nickel<br />
surface, through to the copper, can cause damage to the contacts and elastomers<br />
and should be replaced or repaired.<br />
Figure 1: Example of a load<br />
board pattern.<br />
NOTE: Excessive load board wear is typically caused by contact deflection or<br />
excessive force on the socket housing.<br />
Contactor <strong>Inspection</strong><br />
CAUTION: Use special care during the inspection process. Excessive force can<br />
fracture the housing slots.<br />
Before removing contactor from the load board, use a minimum of 10X magnification<br />
to inspect it for:<br />
• Damaged, missing or excessively worn contacts<br />
• Debris and mold flash trapped around contacts<br />
• Cracks or chipping in the housing or alignment plate<br />
• Cracked, deformed or missing contact slot walls<br />
• Worn alignment plate (ALPL) walls (see Figure 2).<br />
Figure 2: Example of worn (vs.<br />
not worn on right) alignment<br />
plate wall.<br />
Complete alignment plate analysis is a more complex topic than can be fully<br />
addressed here, but the following quick check-up may be helpful.<br />
NOTE: Remove contactor from load board (per instructions on Pages 14) to test<br />
for alignment plate wear. On a backlit surface, place device into the alignment<br />
plate opening and then push it to one corner (see Figure 3).<br />
Figure 3: Example of backlit<br />
alignment plate wear test.<br />
Use a feeler gauge stock of 0.1mm, to check the gaps on the opposite sides.<br />
If feeler gauge stock slips in and out of gap easily, the alignment plate may<br />
need to be replaced. Worn handler alignment pin holes (contact your <strong>Johnstech</strong><br />
Representative for bushings to reduce contactor wear.)<br />
If any of the above conditions are observed, contactor maintenance and possibly<br />
contact/elastomer or alignment plate replacement is required.<br />
Figure 4: Examples of tail stop<br />
wall wear.<br />
www.johnstech.com<br />
©2012 <strong>Johnstech</strong> International Corporation<br />
All rights reserved.<br />
11
Pad ROL 200KR<br />
HOUSING, ELASTOMER & CONTACT INSPECTION<br />
Housing <strong>Inspection</strong><br />
In order to inspect the housing, elastomers and contacts, the contactor must be<br />
removed from load board and disassembled. Refer to instructions on Pages 14-<br />
15.<br />
Figure 5: Acceptable contact<br />
wipe on pad (Matte Tin).<br />
Figure 6: Example of cut<br />
elastomer; replace.<br />
Pad ROL 200KR Kelvin-Ready Contactor housings have a recommended lifespan<br />
of 2,000,000 million insertions. Take the dismounted/disassembled contactor and<br />
using a minimum of 10X magnification, inspect the housing for signs of tail stop<br />
wear. If the tail stop depth exceeds 0.05mm (see Figure 4), replace housing.<br />
Conversely, if the contact wipe on the device pad is not placed correctly (see<br />
Figure 5), check the alignment plate and tail stop wall for wear. If observed,<br />
replace the alignment plate.<br />
Elastomer <strong>Inspection</strong><br />
Using 10X+ magnification, inspect elastomers for signs of:<br />
• Cuts or tears<br />
• Compression set<br />
• Stretched sections<br />
Pad ROL 200KR Kelvin-Ready Elastomers should last to 300,000 insertions,<br />
but there are many factors that affect elastomer life. Upon inspection, if you<br />
see excessively cut or torn elastomers (see Figure 6), or if the compression<br />
set exceeds 0.05mm (see Figure 7), replace elastomers to regain optimum<br />
performance.<br />
Figure 7: Example of<br />
compression set; replace.<br />
Contact <strong>Inspection</strong>/Sense Contact <strong>Inspection</strong><br />
Using 10X+ magnification, inspect contacts for signs of:<br />
• Worn Tips (see Figure 8)<br />
• Scratches or Markings<br />
• Oxide Buildup (see Figure 9)<br />
• Debris Buildup<br />
• Compressed/Distorted Shape<br />
Using 10X+ magnification, inspect sense contacts for signs of compressed/<br />
distorted shape at the tips (see Figure 10).<br />
Figure 8: Worn tips of contacts.<br />
observe worn tip for contact on<br />
the right.<br />
If any of the conditions listed above are observed, discard used contacts and<br />
replace with new ones. Also, for optimum performance, if you know the contacts<br />
have run their recommended lifespan, or you can see that wear exceeds 0.10mm,<br />
replace with new contacts.<br />
Figure 9: Example of oxide build<br />
up on contact tip (photo is from a<br />
test on Matte Tin).<br />
Debris Buildup<br />
The self-cleaning wipe-action of ROL Technology is designed to greatly reduce<br />
the amount of debris buildup on contacts. However, some debris buildup will<br />
occur if contactors are unused for 2 or more days, appearing dull gray in color (see<br />
Figure 9). A light brushing or a few device insertions will typically remove the debris<br />
barrier and expose a shiny surface. Clean the contactor after prolonged downtime<br />
or if you experience a decrease in yields. Refer to cleaning procedures on Pages<br />
16-17.<br />
NOTE: If contacts have significant/excessive debris build-up, check all<br />
components in the test cell to ensure that device alignment and plunge depth are<br />
correct.<br />
Figure 10: Bent tine of sense<br />
contact.<br />
12<br />
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Pad ROL 200KR<br />
CONTACTOR REMOVAL AND INSTALLATION<br />
Contactor Removal & Installation Instructions<br />
It is recommended that you remove your Pad ROL 200KR Kelvin-Ready Series<br />
Contactor from the load board before performing any component inspection,<br />
cleaning and/or maintenance.<br />
Step 1: Remove Contactor<br />
Start removal of the contactor from the load board by loosening the fasteners. Use<br />
a microscope, to watch for contacts or ground Insert sticking to the mounting surface<br />
while carefully lifting contactor from load board. If either is sticking, apply several<br />
drops of Isopropyl Alcohol through contact slots and allow it to soak for two minutes.<br />
Once free, inspect it for any loose or missing contacts. Mount the contactor to the<br />
acrylic shipping plate (shown on Page 5).<br />
Step 2: Perform <strong>Maintenance</strong> & Cleaning<br />
Perform the maintenance and cleaning per the instructions contained on the<br />
following pages.<br />
Step 3: Clean Load Board<br />
Before remounting the contactor to the load board, ensure that no debris is present<br />
in the interface area. If necessary, use compressed air and/or Isopropyl Alcohol<br />
with a clean lint-free cloth to carefully wipe the bottom of the contactor and the<br />
surface of the load board clean.<br />
Figure 10: Screw tightening<br />
pattern.<br />
Recommended<br />
Torque Values<br />
in.-lb. Nm<br />
0-80 1.0 0.11<br />
2-56 2.0 0.23<br />
4-40 5.0 0.56<br />
M1.4 x 0.3 0.4 0.04<br />
M1.6 x 0.35 0.6 0.06<br />
M2 x 0.40 1.3 0.15<br />
M2.5 x 0.45 2.5 0.28<br />
M3 x 0.5 4.5 0.51<br />
M4 x 0.7 8.0 0.90<br />
NOTE: NEVER use Acetone or other solvents.<br />
Step 4: Install Contactor<br />
Refer to the load board drawing that was sent with either your quote or order for<br />
proper footprint layout. Fasten the contactor to the load board by fitting the screws<br />
through the contactor assembly and engaging several threads. Under a microscope<br />
or 10X eye loupe, inspect the contact tips for alignment. Misaligned contacts can<br />
damage the alignment plate, housing and load board. Use the elastomer tool to<br />
realign the contacts where necessary. Evenly tighten the fasteners in a crisscross<br />
pattern (see Figure 10). To avoid damage to the contactor or threaded inserts in the<br />
load board, the contactor mounting screws should be tightened, according to the<br />
Recommended Torque Values in the table at left.<br />
Step 5: Verify Contacts<br />
Verify that all contacts are properly positioned. Gently actuate all of the contacts with<br />
an elastomer tool to ensure proper contact motion.<br />
Step 6: Verify Test Set-up<br />
Verify the device-to-contactor alignment and handler plunge depth, as well as the<br />
X-Y presentation.<br />
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13
Pad ROL 200KR<br />
SENSE CONTACT & ELATOMER REMOVAL<br />
INSTRUCTION<br />
CAUTION: Avoid putting pressure on slot walls and webs by not resting<br />
hands or tools in these areas while working on the contactor.<br />
Step 1: Remove Alignment Plate<br />
• See Step 2 on Page 17.<br />
Figure 11: Remove top housing<br />
cover plate.<br />
Step 2: Remove Top Housing Cover Plate<br />
• See Figure 11.<br />
Step 3: Remove Sense Contact Elastomers<br />
• Flip the top housing cover plate top side down and grasp one end of the green elastomer with<br />
tweezers (see Figure 11).<br />
• Lift and peel the elastomer out of the groove from one end to the other (see Figure 12).<br />
Figure 12: Remove top housing<br />
cover plate elastomer.<br />
Figure 13: Top view. Removing<br />
retention elastomer of sense<br />
contacts.<br />
Step 4: Remove Sense Contact Retention Elastomer<br />
• From the top side of the contactor use the tweezers to pull out the blue retention elastomer from all<br />
four sides of the contactor (see Figure 13).<br />
• Inspect elastomers per instructions on Page 13 to determine whether elastomers can be reused or<br />
need to be discarded.<br />
Step 5: Remove Sense Contacts<br />
• From the top side of the contactor use tweezers to slide the sense contact to the back of the<br />
retention elastomer slot (see Figure 14).<br />
• Grab the sense contact rear with the tweezers and lift up, rotate the contact tips up during removal<br />
(see Figure 14).<br />
• If your intent is just to change out the elastomers and reuse the contacts, take extra care in the<br />
removal process. Do not squeeze or bend them and do not touch the tips. Damaged tips can affect<br />
performance.<br />
• Either discard worn contacts or set aside for reassembly.<br />
NOTE: 25mm x 25mm housing designs are one-piece. Install the green retention<br />
elastomer in the alignment plate.<br />
Tweezers<br />
Sense Contact<br />
Figure 14: Remove sense<br />
contact.<br />
Retention<br />
Elastomer<br />
Slot<br />
14<br />
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Pad ROL 200KR<br />
FORCE (ROL) CONTACT & ELASTOMER REMOVAL<br />
INSTRUCTIONS<br />
CAUTION: Avoid putting pressure on slot walls and webs by not resting hands or<br />
tools in these areas while working on the contactor.<br />
Step 1: Remove Inner/Front Force (ROL ) Contact Elastomers<br />
• Turn contactor over so load board side faces up.<br />
• Use tweezers to pull out the inner/front (blue) elastomer from all four sides of the contactor (see<br />
Figure 15).<br />
• Inspect elastomers per instructions on Page 13 to determine whether elastomers can be reused or<br />
need to be discarded.<br />
Step 2: Remove Force (ROL ) Contacts<br />
• With contactor still load board side up, use tweezers to carefully pull Force (ROL ) contacts out of<br />
housing (see Figure 16).<br />
• Many people find it easier to start at one corner and work your way around the contactor but<br />
removal order is unimportant.<br />
• Inspect contacts to determine if they need to be discarded or can be reused. Refer to Page 13 for<br />
help.<br />
• If your intent is just to change out the elastomers and reuse the contacts, take extra care in the<br />
removal process. Do not squeeze or bend them and do not touch the tips. Damaged tips can affect<br />
performance.<br />
• Either discard worn contacts or set aside for reassembly.<br />
Figure 15: Removal of inner/front<br />
elastomer.<br />
Figure 16: Contact removal.<br />
Step 3: Remove Outer/Back Force (ROL ) Contact Elastomers<br />
• Like in Step 1 above, use tweezers to pull out the outer or back elastomers (see Figure 17).<br />
• Inspect for signs of wear per instructions on Page 13 and either set aside for<br />
reinstallation or discard.<br />
NOTE: It is recommended to just discard used elastomers and assemble contactor<br />
with new ones, but if they are in exceptionally good shape, they can be set aside<br />
and reinstalled. Blow with compressed air before reinstalling. Dip the elastomers in<br />
Isopropyl Alcohol to clean.<br />
Figure 17: Pull out outer/back<br />
elastomer<br />
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15
Pad ROL 200KR<br />
CONTACTOR CLEANING<br />
Light Cleaning Procedure<br />
If debris buildup is observable upon inspection of the contactor or you experience a<br />
drop in yields or an increase in resistance, follow the Light Cleaning Procedure on<br />
this page.<br />
Figure 18: Separating housing<br />
and alignment plate.<br />
NOTE: A Fiberglass brush is best for contactor cleaning but if you don’t have<br />
or are not allowed to use a fiberglass brush, a nylon brush may be used as a<br />
substitute.<br />
Step 1: Remove Contactor from Load Board<br />
• Refer to instructions on Page 14, Step 1.<br />
Step 2: Remove Alignment Plate<br />
• Use a scalpel to gently pry apart the housing and alignment plate, working in an even and<br />
incremental manner around the housing to avoid binding (see Figure 18).<br />
Figure 19: Top view. Correct<br />
direction for contact brushing on<br />
the top side of the contactor.<br />
Step 3: Brush the Top Side of Contactor<br />
• Mount contactor to the acrylic mounting plate.<br />
• Use a fiberglass (or nylon) brush to gently clean the perimeter force and sense contact tips and<br />
ground (even if in a ground insert) contact tips. Always brush from the outside in, towards the<br />
center of the contactor (see Figure 19).<br />
CAUTION: When brushing a bank of sense contacts, be careful not to brush into<br />
another bank of contacts at the same time, as this may damage the sense contact<br />
tips. Brush under a microscope.<br />
• If needed, wet the fiberglass brush with Isopropyl alcohol to aid in debris removal.<br />
Figure 20: Bottom view. Correct<br />
direction for contact brushing on<br />
the sense contacts.<br />
Step 4: Brush the Bottom Side of Contactor<br />
• Remove contactor from the acrylic mounting plate and turn over so the load board side is up.<br />
• Use the fiberglass (or nylon) brush again to gently clean the perimeter force and sense contact<br />
bottoms from the center of the contactor outward (see Figure 20). Avoid brushing the elastomers<br />
Step 5: Clear Debris<br />
Remove any loose debris from the contactor using one or both of these methods:<br />
• A small vacuum.<br />
• Dry, clean compressed air (20psi or less) (see Figure 21).<br />
Be sure to thoroughly clear debris from every part of the contactor, including the<br />
elastomer and contact slots. If no loose debris remains, the contactor may be<br />
reassembled and reinstalled.<br />
NOTE: If remaining debris or foreign matter is observed, even after performing this<br />
light cleaning procedure, try the thorough cleaning procedure on the next page.<br />
Figure 21: Compressed air<br />
cleaning.<br />
Step 6: Clean Handler<br />
• Clean the handler per the manufacturer’s recommendations.<br />
Step 7: Reinstall Contactor<br />
• If no loose debris remains on the contactor, remount it to the load board per the instructions on<br />
Page 14, Step 4.<br />
NOTE: Before reassembling the alignment plate to the housing, make sure the<br />
sense contacts are laying flat in the housing grooves. See picture at the bottom left<br />
of Page 22.<br />
16<br />
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Pad ROL 200KR<br />
CONTACTOR CLEANING<br />
Thorough Cleaning Procedure<br />
If the contactor and alignment plate have excessive debris buildup, it is strongly<br />
recommended to perform a thorough cleaning with an ultrasonic cleaner. Only<br />
execute this procedure in a well ventilated area with an exhaust hood.<br />
CAUTION: The ultrasonic cleaner should have a maximum power of 500W and a<br />
catch basket in the tank that prevents the contactor from touching settled debris.<br />
Step 1: Prepare the Housing<br />
• Remove the contactor from the load board per instructions on Page 14, Step 1.<br />
• Gently pry apart the housing and alignment plate per instructions in Step 2 on Page 17.<br />
• Remove ground insert if contactor has one, Refer to Ground Insert Removal Instructions on Page<br />
27.<br />
• If contacts and elastomers require replacement for either the housing or ground insert, removed<br />
the used contacts and elastomers.<br />
• If the contacts and elastomers are in good condition they can be left in the housing during the<br />
following cleaning procedures.<br />
Figure 22A: Example of cleaning<br />
a housing in an ultrasonic<br />
cleaner; with a beaker to contain<br />
the odor from distilled white<br />
vinegar.<br />
Step 2: Prepare the Bath<br />
• Prepare a bath of diluted Isopropyl Alcohol (70/30 Alcohol/Water) OR a heated (40-50ºC max)<br />
mild acidic/distilled white vinegar (7.1 > ph > 3.0) solution.<br />
NOTE: If a sonic cleaner is unavailable, gently brush the housing with bath solution<br />
(see above), rinse in deionized water and dry out housing completely.<br />
Figure 22B: Example of cleaning<br />
a housing in an ultrasonic<br />
cleaner; note left position.<br />
NOTE: The mild acidic/distilled white vinegar may have a strong odor. To contain<br />
the odor we recommend using a beaker cover (see Figure 22A).<br />
Step 3: Perform the Cleaning<br />
• Operate ultrasonic cleaner per manufacturer’s instructions only.<br />
• Fully immerse the populated or unpopulated housing device-side down. The bath should be preheated<br />
and run for a minimum of a 30 minute cycle (see Figure 22B).<br />
• Also, place the alignment plate and the ground insert into the bath.<br />
• Remove housing, alignment plate and ground insert from the bath/sonic rinse and rinse with<br />
deionized water for about 10 minutes (see Figure 23).<br />
NOTE: For populated contactor housings or populated ground inserts, inspect<br />
for missing contacts before moving them to the rinse bath. Some contacts may<br />
dislodge during the ultrasonic cleaning. Collect them and move them to the rinse<br />
bath and then reinstall before drying.<br />
Figure 23: Example of rinsing a<br />
housing in an ultrasonic cleaner;<br />
note right position.<br />
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17
Pad ROL 200KR<br />
CONTACTOR CLEANING<br />
Step 4: Dry the Contactor<br />
Current leakage may occur during testing if moisture remains on the contacts. To<br />
prevent this:<br />
• Carefully pat the contactor dry with a lint-free cloth.<br />
• Blow the contactor dry with heated air (see Figure 24).<br />
• If necessary, place in oven for approx. 10 minutes.<br />
Figure 24: Heated air drying, a<br />
common hair dryer will suffice.<br />
CAUTION: DO NOT use heat guns to blow contactors dry. Heated air should not<br />
exceed 100ºC or be utilized for longer than 30 minutes.<br />
Step 5: Reassemble the Contactor<br />
• Reassemble the contactor per instructions on Pages 18-19.<br />
Step 6: Reinstall Contactor<br />
• Inspect contactor one final time for any debris, damage or moisture.<br />
• Remount contactor to load board per instructions on Page 14, Step 4.<br />
18<br />
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Pad ROL 200KR<br />
ELASTOMER INSTALLATION<br />
Elastomer Installation Instructions for Force Contacts of Kelvin-<br />
Ready Contactor<br />
Before beginning, use low-pressure, clean compressed air on Contactor to blow away<br />
any debris.<br />
Step 1: Cut Elastomers to Length<br />
• Turn contactor load board side up.<br />
• Lay a length of the red elastomer next to the outer or back elastomer slot.<br />
• Use a blade to mark the elastomer at the correct length (see Figure 25), which is just a little short<br />
of the end well (see Figure 26). Use care to not cut the housing.<br />
• Use micro-scissors to cut elastomer straight across.<br />
• Cut remaining 3 lengths of the outer/back (red) elastomers to this same size.<br />
• Proceed on to cut the 4 inner/front elastomers (blue) to this same length.<br />
• Store unused elastomer in original packaging only.<br />
Step 2: Install Outer/Back Elastomers<br />
• Place a red elastomer over the outer/back elastomer slot.<br />
• Using an elastomer tool, gently push elastomer into slot (see Figure 27).<br />
• Elastomer should extend just slightly less than the end of the end well.<br />
• Continue installing remaining (red) outer elastomers.<br />
Step 3: Install Inner/Front Elastomers<br />
• Place elastomer (blue) over the inner or front elastomer slot.<br />
• Position tweezers over the contact rib in the middle of the elastomer slot, then gently squeeze<br />
the elastomer and tuck it into the elastomer slot (see Figure 28). Continue working towards the<br />
right, “pinching and tucking” at each rib in sequence (see Figure 28). Use a delicate touch when<br />
squeezing elastomer to avoid nicks and cuts.<br />
• Once the right side is completed, go back to the center and work toward the left. Finish by pushing<br />
elastomer ends into end wells. Check to make sure elastomer just barely extends into the end<br />
wells (see Figure 29).<br />
• If the elastomer appears off-center, please pull it out and reinstall. Optimum performance is<br />
achieved when elastomers are centered in the elastomer slot.<br />
NOTE: Lubricate elastomers with Isopropyl Alcohol, if needed, to facilitate<br />
installation. Please use special care to avoid bunching, stretching or twisting the<br />
elastomer. Proper elastomer installation helps optimize performance.<br />
Figure 25: Mark elastomer at<br />
appropriate length.<br />
Figure 26: Proper fit of<br />
elastomers into end wells.<br />
Figure 27: Use elastomer tool to<br />
push elastomer into outer slot.<br />
• Continue installing the remaining inner elastomers.<br />
• Please note that they will fit more snugly into the inner elastomer slots than how it was for the outer<br />
elastomers.<br />
Figure 28: Use tweezers<br />
to gently “pinch and tuck”<br />
elastomer into inner elastomer<br />
slot.<br />
Figure 29: Work from center to<br />
right and then center to left.<br />
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19
Pad ROL 200KR<br />
Tips<br />
CONTACT INSTALLATION<br />
Contact Installation Instructions For Sense Contacts<br />
NOTE: Sense contacts must be installed before installing the sense elastomers.<br />
Figure 30: Top view. Grab<br />
contact at rear tail bend and<br />
rotate tip about 45 degrees.<br />
Sense Elastomer<br />
Retention Slot<br />
Step 1: Align and Insert Contact<br />
• Turn contactor device side up.<br />
• Use tweezers to grab the contact at the rear tail bend.<br />
• Rotate the contact tips up about 45 degrees (see Figure 30).<br />
• Start installation at the far left contact groove on any side. Align the contact above the contact<br />
groove and insert contact tail into the sense elastomer retention slot and into the tail guide slot (see<br />
Figure 30 & 31).<br />
• Rotate the contact tips back down so that the contact lays flat in the groove (see Figure 31).<br />
Step 2: Position Contact and Insert Further<br />
• Use the tweezers to slide the contact towards the center of the contactor until the contact tail<br />
touches the tail stop (see Figure 31 & 32).<br />
Tail <strong>Guide</strong><br />
Slot<br />
Figure 31: Use tweezers to drop<br />
contact into place.<br />
Tail Stop<br />
Figure 32: Fully assembled<br />
sense contact.<br />
20<br />
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Pad ROL 200KR<br />
ELASTOMER INSTALLATION<br />
Elastomer Installation Instructions for Sense Contacts of Kelvin-<br />
Ready Contactor<br />
Before beginning, use low-pressure, clean compressed air on contactor to blow away<br />
any debris.<br />
Step 1: Cut Retention Elastomers to Length<br />
• From the top side of the contactor, lay a length of blue elastomer next to the sense contact retention<br />
slot.<br />
• Use a blade to mark the elastomer at the correct length, which is slightly short of the slot ends. Use<br />
care not to cut the housing (see Figure 33).<br />
• Use micro scissors to cut the elastomer straight across.<br />
• Cut the remaining 3 lengths of retention slot elastomers to this same size.<br />
• Store unused elastomer in original packaging only.<br />
Step 2: Install Blue Retention Elastomers<br />
• Place the blue elastomer over the Kelvin Contact retention slot.<br />
• Using an elastomer tool, push the elastomer fully into the slot (see Figure 34).<br />
Continue installing remaining retention elastomers.<br />
Sense Contact Retention Slot<br />
Figure 33: Top view. Cut blue<br />
elastomer to length.<br />
Figure 34: Use elastomer tool to<br />
push elastomer into slot.<br />
Step 3: Cut Cover/Alignment Plate Elastomers<br />
• With cover plate removed, turn cover plate top side down.<br />
• Lay a length of green elastomer next to the alignment plate elastomer slot.<br />
• Use a blade to mark the elastomer at the correct length, which is slightly short of the pocket ends.<br />
Use care not to cut the alignment plate (see Figure 35).<br />
• Use micro scissors to cut the elastomer straight across.<br />
• Cut the remaining 3 lengths of alignment plate elastomers to this same size.<br />
• Store unused elastomer in original packaging only.<br />
Step 3: Install Alignment Plate/Cover Elastomers<br />
• Tuck one end of the elastomer into one of the groove pockets (see Figure 36).<br />
• Proceed to tuck the length of the elastomer into the groove (see Figure 38) and tuck the opposite<br />
end into the remaining groove pocket.<br />
• Continue installing the remaining alignment plate/cover elastomers.<br />
Figure 35: Cut elastomer straight<br />
across.<br />
Figure 36: Bottom view. Lay a<br />
length of red elastomer next to<br />
the alignment plate and place<br />
in slot.<br />
Figure 37: Fully installed sense<br />
contacts and blue retention slot<br />
elastomers.<br />
Figure 38: Bottom view. Fully<br />
installed alignment plate/cover<br />
elastomers.<br />
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21
Pad ROL 200KR<br />
CONTACT INSTALLATION<br />
Contact Installation Instructions For Force (ROL ) Contacts<br />
CAUTION: Avoid putting pressure on slot walls and webs by not resting hands or<br />
tools in these areas while working on the contactor.<br />
Figure 37: Align above and<br />
between elastomers.<br />
Step 1: Align and Insert Contact<br />
• Turn contactor load board side up.<br />
• Using tweezers, dip contact in Isopropyl Alcohol. (The alcohol lubricates the contact, making<br />
insertion easier.)<br />
• Start installation at the far left contact slot on any side.<br />
Align the contact above the contact slot (see Figure 37) and press the contact down between the<br />
gap in the elastomers (see Figure 38).<br />
Step 2: Position Contact and Insert Further<br />
• Maneuver the head of the contact down and towards the center of the contactor (see Figure 39).<br />
Step 3: Final Adjustment<br />
• Use tweezers to gently rotate the contact tail down onto the outer (Red) elastomer until the fit is<br />
snug (see Figure 40).<br />
Figure 38: Insert downward into<br />
gap between elastomers.<br />
Step 4: Installation Pattern<br />
• Continue installing contacts in the repeating left-right-center sequence shown below, per the steps<br />
above, until entire side is populated. Proceed on to each side in the same manner.<br />
Figure 39: Gently push contact<br />
head towards center of contactor.<br />
1 4 6 3 5 2<br />
Contact Insertion Order<br />
NOTE: It is recommended to mount the contactor onto the acrylic mounting<br />
late as shown on Page 5 when not in use or for inspecting, storing or<br />
shipping. If the contactor is stored on acrylic mounting plate for over a week,<br />
loosen screws to avoid compression set on the rear elastomer.<br />
Figure 40: Gently push contact<br />
tail down onto red elastomer.<br />
22<br />
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Pad ROL 200KR<br />
INSTALLATION VERIFICATION<br />
In order to ensure optimum performance from your Pad ROL 200KR Kelvin-Ready<br />
Contactor, it is very important to check and make sure that the contacts and<br />
elastomers are properly installed.<br />
Turn your contactor load board and follow these steps to make sure the contacts<br />
and elastomers of your Pad ROL 200KR Kelvin-Ready Contactor are installed<br />
correctly.<br />
Step 1: With Cover Plate and Alignment Plate installed and the Contactor<br />
fastened to the load board, check Sense and Force (ROL ) Contacts<br />
• Verify that the sense contacts and Force (ROL ) contacts do not touch.<br />
• The sense contact tips should sit at or below the top of the Force (ROL ) Contact tip.<br />
NOTE: The contacts may need to be actuated by a device to properly seat all<br />
contacts.<br />
Sense Contact<br />
Notice the open<br />
space between<br />
Sense and Force<br />
(ROL ) Contact. Force (ROL )<br />
Contact<br />
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23
Pad ROL 200KR<br />
INSTALLATION VERIFICATION<br />
Step 2: Check the Force (ROL ) Contact Elastomers<br />
Make sure the Force (ROL ) Contact Elastomers are:<br />
• At least halfway into the end wells.<br />
• Not stretched, bunched or twisted.<br />
Sense Contacts<br />
Step 3: Verify Sense Contacts<br />
• Verify that the sense contact tails are aligned with the recessed grooves on load board side of<br />
housing (see picture above).<br />
NOTE: The sense contact tails should be sticking out a bit from the housing (see<br />
picture on left). They should also all be at the same height above the housing floor<br />
to assure there is equal force on each load board pad.<br />
24<br />
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Pad ROL 200KR<br />
GROUNDING SOLUTIONS<br />
The Pad ROL 200KR Kelvin-Ready offers four main Grounding Options:<br />
RCI: ROL Contacts in a Copper Insert, for 5x5-12x12 packages.<br />
• New Elastomer retention design (see Figure 41).<br />
CI: Copper Insert for 3x3 packages (see Figure 42).<br />
EI: Eco -1 Insert for 3x3 & 4x4 packages (see Figure 43).<br />
• See the EI Insert Owners Manual, Lit 1413A.<br />
Figure 41: RCI ground insert<br />
(New elastomer retention<br />
design).<br />
RTH: ROL Contacts in Torlon Housing, for 4x4-12x12 packages (refer to Page<br />
21).<br />
In order to maintain proper operation and ensure a long life for your grounding<br />
solution, you will need to perform cleaning and maintenance, much like you need to<br />
do for the other components of your Pad ROL 200KR Kelvin-Ready Contactor.<br />
Ground Inserts<br />
RCI, CI and EI ground inserts need to be removed for cleaning and maintenance per<br />
the instructions on Page 26. Then follow the Cleaning & Installation instructions on<br />
Page 26.<br />
Figure 42: CI ground insert.<br />
Ground Contact <strong>Maintenance</strong><br />
<strong>Inspection</strong>, cleaning and change-out of the ground contacts & elastomers can<br />
be performed in the same manner as the perimeter contacts and elastomers.<br />
(However, please note that depending on which way the ground contacts are<br />
oriented, the direction of brushing when performing the Light Cleaning Procedure<br />
will vary.)<br />
NOTE: Examples shown are non-Kelvin configurations. Refer to standard Pad <br />
ROL200 M&I <strong>Guide</strong> for the latest elastomer configurations.<br />
Figure 43: EI ground insert.<br />
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25
Pad ROL 200KR<br />
GROUND INSERT MAINTENANCE<br />
Ground Insert Removal Instructions<br />
IMPORTANT: Use finger cots when handling ground inserts to avoid<br />
contamination with skin oils, which can degrade performance.<br />
Figure 44: A light downward<br />
push will free ground insert from<br />
housing.<br />
Using covered fingers and/or the elastomer tool, press down on the ground Insert.<br />
The insert will easily release out of the housing (see Figure 44).<br />
Ground Insert Cleaning Instructions<br />
Step 1: Remove Contacts & Elastomers<br />
• Once the ground insert is removed from the housing, follow instructions for contact and elastomer<br />
removal on Page 15.<br />
Step 2: Clean Ground Insert<br />
• Clean the unpopulated ground insert with a fiberglass (or nylon) brush per the instructions on<br />
Page 16.<br />
• Follow up with ultrasonic cleaning, per instructions on Page 17.<br />
• Inspect for mushrooming or bending. If observed, contact <strong>Johnstech</strong> Field Service or your<br />
Representative.<br />
Step 3: Re-assemble Ground Insert<br />
• Follow the instructions for elastomer & contact installation on Pages 19 & 20.<br />
Step 4: Blow with Compressed Air<br />
• To clear away any remaining debris, blow the insert with compressed air before reinstalling ground<br />
insert. Inspect for remaining debris. If observed, repeat cleaning process again as seen on Page<br />
17.<br />
26<br />
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Pad ROL 200KR<br />
GROUND INSERT INSTALLATION<br />
New Elastomer Retention Ground Insert Design<br />
IMPORTANT: Always ensure ground insert is clean before installing and inspect<br />
used inserts for damage or wear.<br />
Elastomer<br />
retention<br />
grooves<br />
Ledges<br />
Step 1: Locate and Position the Ground Insert<br />
• Under magnification locate your ground Insert and flip the insert right side up and lay on a flat<br />
surface.<br />
Step 2: Installation of the Ground Insert<br />
• With the housing right side up, place the housing over the insert to begin the installation.<br />
• Locate the two grooves on the insert (one on either side) to help guide the housing over the insert<br />
and position the housing over the insert (see Figure 45).<br />
• Line up the ledges from the top of the housing with the elastomer grooves in the ground insert.<br />
NOTE: When the housing and insert are properly oriented, the housing will drop<br />
completely down flat onto the insert. The top of the insert will protrude slightly above<br />
the top surface of the housing. Do not force the insert and housing together. If the<br />
housing does not drop completely down onto the insert, the parts are not oriented<br />
properly.<br />
•<br />
Step 3: Install Blue Retention Elastomer<br />
Insert the two blue retention elastomers (from the top side) along the sides of the insert.<br />
• Cut the blue elastomers to the correct length, not exceeding the channel opening (see Figure 46 &<br />
47).<br />
• Use the probe tool shown on Page 8.<br />
Figure 45: Position the housing<br />
over the RCI ground insert.<br />
Figure 46: Insert the two blue<br />
retention elastomers. (cutaway<br />
view).<br />
NOTE: Retention elastomers are installed on the sides of the insert.<br />
NOTE: The blue retention RCI Elastomers are not the same as the blue ROL Low-<br />
Force XLK Elastomers. The retention elastomers are much smaller in diameter and<br />
are a translucent blue color.<br />
Figure 47: Insert the two blue<br />
retention elastomers. (top view).<br />
NOTE: Examples shown are non-Kelvin configurations. Refer to standard Pad<br />
ROL200 M&I <strong>Guide</strong> for the latest elastomer configurations.<br />
Figure 48: Proper installation of<br />
elastomers, contacts and insert.<br />
(bottom view).<br />
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27
Pad ROL 200KR<br />
All statements, technical<br />
information and recommendations<br />
related to the Seller’s products<br />
are based on information believed<br />
to be reliable, but the accuracy<br />
or completeness thereof is not<br />
guaranteed. Before utilizing the<br />
product, the user shall determine<br />
the suitability of the product for its<br />
intended use. The user assumes<br />
all risks and liability whatsoever<br />
in connection with such use. Any<br />
statements or recommendations of<br />
the Seller which are not contained<br />
in the Seller’s current publications<br />
shall have no force or effect unless<br />
contained in an agreement signed<br />
by an authorized officer of the<br />
Seller. The statements contained<br />
herein are made in lieu of all<br />
warranties expressed or implied,<br />
including but not limited to the<br />
implied merchantability and fitness<br />
for a particular purpose which<br />
warranties are hereby expressly<br />
disclaimed. Seller shall not be liable<br />
to the user or any other person<br />
under any legal theory, including<br />
but not limited to negligence or<br />
strict liability, for any injury or<br />
for any direct or consequential<br />
damages sustained or incurred by<br />
reason of the use of any of Seller’s<br />
products or services that were<br />
defective.<br />
Worldwide Headquarters<br />
1210 New Brighton Boulevard<br />
Minneapolis, MN 55413-1641 USA<br />
Tel: 612.378.2020<br />
Fax: 612.378.2030<br />
E-mail: info@johnstech.com<br />
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Regional/Field Service Office — California, USA<br />
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Tel: 408.448.2020<br />
Fax: 408.448.2030<br />
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Tel: 65.6659.2022<br />
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For questions about anything contained in this <strong>Maintenance</strong> & <strong>Inspection</strong> <strong>Guide</strong>,<br />
contact your local <strong>Johnstech</strong> representative.<br />
If you are experiencing a technical problem or issue, complete the form at:<br />
www.johnstech.com/support or contact the nearest field service office.<br />
© Copyright 2012 <strong>Johnstech</strong> International<br />
Corporation Specifications subject to change.<br />
Specifications subject to change without notice.<br />
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including photocopying, recording or<br />
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without expressed written permission from<br />
<strong>Johnstech</strong>. <strong>Johnstech</strong> and <strong>Johnstech</strong> logo are<br />
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countries. <strong>Johnstech</strong> products and components<br />
are covered by patents and copyrights in the<br />
USA and other countries.<br />
28<br />
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Your Contact For Higher Performance<br />
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