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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 />

www.johnstech.com<br />

Regional/Field Service Office — California, USA<br />

2450 Scott Boulevard<br />

Santa Clara, CA 95050-2504<br />

Tel: 408.448.2020<br />

Fax: 408.448.2030<br />

www.johnstech.com<br />

Regional/Field Service Office — Singapore<br />

33 Ubi Ave 3, #02-37<br />

Vertex Building<br />

Singapore 408868<br />

Tel: 65.6659.2022<br />

www.johnstech.com<br />

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 />

No part of this document may be reproduced<br />

in any form or by any means, electronic or mechanical,<br />

including photocopying, recording or<br />

by any information storage or retrieval system,<br />

without expressed written permission from<br />

<strong>Johnstech</strong>. <strong>Johnstech</strong> and <strong>Johnstech</strong> logo are<br />

registered trademarks in the USA and other<br />

countries. <strong>Johnstech</strong> products and components<br />

are covered by patents and copyrights in the<br />

USA and other countries.<br />

28<br />

ISO 9001:2000 Certified<br />

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All rights reserved.<br />

Your Contact For Higher Performance<br />

LIT 1453-0912. Printed in the USA on 100% Post-Consumer Recycled Paper made utilizing Wind Power.

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