Maintenance & Inspection Guide Edge 400A Series - Johnstech

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Edge 400a SeriesContactor Installation and RemovalYour Edge 400a Series Contactor must be removedfrom the Load Board and disassembledbefore performing any major inspection, cleaningand/or maintenance.NOTE: If you are performing the initial installationof a (new) Contactor onto a (new) LoadBoard, please skip to Step 7.Step 1— Inspect Contactor before RemovalUsing an Eye Loupe (minimum of 10X magnification), inspectthe Contactor and Components for any damage or wear. Noteareas of concern to look at closer once Contactor is removedfrom the Load Board. See Figure 1 for an example of a GoodContactor Assembly.Figure 1: 10X magnificationlooking down near Voltage Key.This is an example of a GoodContactor Assembly. Note howContacts appear in center oftheir slots.Step 2— Remove Contactor from Load BoardRemove Contactor from Load Board by loosening the MountingScrews/Fasteners. You do not have to follow any particularorder. (If you are utilizing Manual Ejector Levers, pushdown on them to free Contactor from Load Board.) Carefullylift Contactor away.Step 3— Inspect ContactorContactor must be disassembled (follow Disassembly Instructionson Page 12) before performing a thorough Inspection ofthe Contactor and it’s Components (Alignment Plates, Contacts,Elastomers, Guide Rails, Housing, Voltatge Key). Specificallylook for any gouges, scratches, cracks, breaks or excessivewear. Refer to Pages 13-15 for detailed directions andphoto examples. What you find will determine the level ofMaintenance and/or Cleaning that is needed.Figure 2: Housing Slots &WallsCAUTION: Avoid putting pressure on the Housing SlotWalls by not resting hands or tools in these areas whileworking on the Contactor. See Figure 2.Step 4— Perform Maintenance/CleaningFrom your inspection (or Troubleshooting a Test Problem fromPage 17), you should have determined which of the ContactorComponents need to be replaced or cleaned. Proceed on tothe Housing Maintenance/Cleaning instructions contained onPages 18-19.Step 5— Reassemble the ContactorFollow the Contactor Reassembly Instructions on Pages 20-21.www.johnstech.com©2009 Johnstech International CorporationAll rights reserved.10
Contactor Installation and RemovalEdge 400a SeriesStep 6— Inspect & Clean Load BoardBefore mounting the cleaned, reassembled Contactor to theLoad Board, inspect the Contact Land Pad Pattern for signs ofwear on the Gold. If visible signs of Nickel are showing, thenmake sure that it is not excessive. It is acceptable to utilizethe Nickel surface during testing; however, in some applications,signal degradation will occur which can impact Yield.Load Boards with wear that extends deeper than the Nickelsurface can cause damage to the Contacts & Elastomers andshould be replaced or repaired.NOTE: Excessive Load Board wear is caused by excessiveContact deflection or force on the Housing.Next, check the interface area to ensure that no debris ispresent. If necessary, use Compressed Air—or IsopropylAlcohol—and a clean, lint-free cloth to carefully wipe thebottom of the Contactor and the surface of the Load Board.Step 7— Mount Contactor to Load BoardNOTE: Johnstech recommends performing a thoroughinspection of the Load Board before initial installationof the Contactor. See Step 6 above. Before inspection,however, verify that your Load Board and Contactormatch each other. Refer to the Load Board Drawingthat was sent to with your Contactor.Fasten Contactor to Load Board by placing the Housing GuidePins into the alignment holes. Next, fit the Mounting Screwsthrough the Contactor Assembly, engaging several threadsby hand. Using a Nut Driver, evenly tighten the MountingScrews in a crisscross pattern shown in Figure 3. To avoiddamage to the Contactor or the threaded inserts in the LoadBoard, the Contactor Mounting Screws should be tightened,according to the Recommended Torque Values in Figure 4.7542136Figure 3: Screw tighteningpatternRecommendedTorque Valuesin.-lb. Nm0-80 1.0 0.112-56 2.0 0.234-40 5.0 0.56M1.4 x 0.3 0.4 0.04M1.6 x 0.35 0.6 0.06M2 x 0.40 1.3 0.15M2.5 x 0.45 2.5 0.28M3 x 0.5 4.5 0.51M4 x 0.7 8.0 0.90Figure 4: RecommendedTorque Values Table8Step 8— Verify ContactsAfter Mounting the Contactor to the Load Board, verify thatall Contacts are properly positioned and evenly spaced acrossthe Elastomers. Insert the Module by hand to actuate theContacts and ensure proper motion.Step 9— Verify Test Set-upVerify the Module-to-Contactor alignment and Handler PlungeDepth, as well as the X-Y presentation. Insert Module intoContactor by manual insertion if using a Manual Loader orauto insertion if using a Handler. Next, remove Module fromContactor and measure the scrub/witness marks:For Centering — Measure from the center of the mark to theoutside of the Pad to the left and then the right. (See Figures24 & 25 on Page 16.) If centered, these measurementsshould be nearly equal.For Plunge Depth — Measure from the end of the Module tothe end of the Scrub Mark. (See Figure 26 on Page 16.) Thismeasurement is the appoximate plunge depth. If the markis not centered or exceeds a 1.60mm Plunge Depth, checkthe set-up of the Handler or Manual Loader.11www.johnstech.com©2009 Johnstech International CorporationAll rights reserved.
Page 1 and 2: Maintenance& InspectionGuideEdge 40
Page 3 and 4: Table of ContentsEdge 400a SeriesSt
Page 5 and 6: Contactor ComponentsEdge 400a Serie
Page 7 and 8: Contactor Configuration & Verificat
Page 9: Recommended Maintenance ToolsEdge 4
Page 13 and 14: Contactor/Component InspectionEdge
Page 15 and 16: Contactor/Component InspectionEdge
Page 17 and 18: TroubleshootingEdge 400a SeriesThis
Page 19 and 20: Contactor CleaningEdge 400a SeriesT
Page 21 and 22: Contactor ReassemblyEdge 400a Serie
Page 23 and 24: NotesEdge 400a Series23©2009 Johns

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