Fci Airmax User manual

FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 1 of 9

Revision A

AIRMAX

STITCHED HEADER

REMOVAL TOOLING

Figure 1

For Use With Removal Of

3x6, 4x16, 4x10, 5x10 Stitched Vertical Headers

FCI MANUAL P/N 10118041-9090

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 2 of 9

Revision A

Table of Contents

INTRODUCTION..................................................................................................................................................................3

General Description ............................................................................................................................................3

Removal Tool Selection......................................................................................................................................3

SAFETY...............................................................................................................................................................4

General Safety Rules...........................................................................................................................................4

Cautions.............................................................................................................................................................4

REMOVAL PROCEEDURE................................................................................................................................5

MAINTENANCE.................................................................................................................................................8

Notes.................................................................................................................................................................8

TOOL DRAWINGS………………………………………………………………………………………………............9

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 3 of 9

Revision A

Introduction

General Description

This instruction manual covers the use and maintenance of the line of Airmax Stitched Header

Removal Tools

The “Airmax Stitched Header Removal Tool” (AHR) is designed to plug into the header, much

as you would a mating receptacle connector. The difference is that the “AHR” tooling is not

required to be fully inserted to extract a damaged connector. Additionally, the removal or

straightening of damaged pins prior to extraction is not required as long as the majority of the

pin field remain within true position. The major consideration is that the correct “AHR” tooling

is used for the header being extracted.

Removal Tool Selection

Dedicated “AHR” tools are available as show below:

•3 x 6 10118861-1000 Keep Out Zone Of 5.0 mm Each Side Of Connector

•4 x 10 10118041-2000 Keep Out Zone Of 2.5 mm Each Side Of Connector

•4 x 16 10118041-1000 Keep Out Zone Of 2.5 mm Each Side Of Connector

•5 x 10 10118860-1000 Keep Out Zone Of 3.1 mm Each Side Of Connector

**Notes:

•“Keep Out Zone” is described as the area to either side of the connector shroud that

must be clear of any other components to permit unrestricted use of the tooling.

•As conformal coatings vary in consistency, it is suggested to apply a strip of tape to

the “Keep Out Zones” of the connector being extracted or the two lower contact

surfaces of the Jack-Frame to protect the board coating during the removal process.

******Please read these instructions thoroughly before using the hand-tool******

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 4 of 9

Revision A

Safety

General Safety Rules

1. Keep Observers Away: All visitors should be kept safe distance from work area.

2. Don’t Force The Tool: It will do the job better and safer at the rate for which it was designed.

3. Use The Correct Tool: Don't force a tool to do a job for which it was not designed.

4. Always Wear Safety Glasses: Everyday eyeglasses only have impact resistant lenses, they are

NOT safety glasses. Safety glasses equipped with side-shields will increase protection against

flying debris resulting from other operations in the proximity.

a. Eye protection should be worn at all times when operating or servicing hand tools.

Safety glasses equipped with side-shields will increase protection against flying debris

resulting from other operations in the proximity.

5. Don’t Overreach: Maintain proper footing and balance at all times. Position the equipment

and supplies within easy reach.

a. A chair with adjustable height should be provided to allow the operator to position their

arms slightly above and parallel to the surface of the backplane / workbench.

6. Maintain Tools With Care: Keep tools clean for best and safest performance.

a. Never use air to blow away debris.

Check For Damaged Tooling: Before further use of the tool, a misused hand tool that appears to

be damaged should be carefully checked to determine that it would operate properly and

perform its intended function. Check for alignment of moving parts, binding of moving parts,

breakage of parts, mounting, and any other conditions that may affect the operation.

7. Storage: The hand tool should be placed in a dry, cool area, covered from dust and dirt.

Cautions

•Do not use wrenches, add extensions to the knob or jack-frame handles or install this hand tool

into any power assisted device. Doing so will damage the hand tool and void any remaining

warranty.

PDS: Rev :A STATUS:Released Printed: Oct 13, 2011

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 5 of 9

Revision A

REMOVAL PROCEEDURE

1. Verify that there is sufficient “keep-out” zone provided on either side of the board-mounted

module sidewalls for the outer standoffs of the Jack-Frame.

•A keep-out zone is an area on the backplane, to either side of a connector that

was designed to use of application and repair tools without concern of damaging

other board mounted components (such as inductors, resistors, diodes &

capacitors).

2. Following the appropriate selection of “AHR” tool that corresponds to the Airmax Stitched

Header to be extracted, the tool is first prepared by turning the Knob counter-clockwise to

lower the Plate Guide towards the end of the tool. When the Pressure Rod has bottomed out in

the slots of the jack frame, continue to turn the Knob a few additional turns counter-clockwise

to obtain a gap to the Nylon Washer and lightly press down on the Knob to verify that the

tooling is fully extended; a preload gap should be remain visible between the Knob and the

Nylon Washer (see Figure 2 below).

•If a preload gap is not visible between the Knob and the Nylon Washer,

continue to rotate the knob counter-clockwise1/2 turn and lightly press down on

the Knob.

Figure 2

Small Gap Between Knob And Washer

3. While lightly pulling upward on the Pressure Rod to keep the Extraction Comb Assembly

disengaged, position the tool over the damaged connector and insert the Plate Guide into the

Airmax Stitched Header, much as you would a mating connector (see Figure 3).

•The Plate Guide does not have to fully seat into the connector shroud to remove

the pins.

•Damaged pins do not have to be straightened or removed as long as the majority

of the pins can be picked up by the tool.

PDS: Rev :A STATUS:Released Printed: Oct 13, 2011

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 6 of 9

Revision A

Figure 3

Removal Tool Inserted Into Connector

(Pressure Rod Raised & Jack-Frame Seated On PCB)

4. Verify that the Plate Guide is at least partially inserted into the header and allow the Jack-

Frame to rest on the backplane. At this point, the tool is positioned and is now followed up

with the clamping of the pins.

5. Evenly apply downward pressure to both sides of the Pressure Rod to lower the comb

assembly; clamping the terminals between the Comb Plates and the Pull Plates.

PRESSURE ROD

Figure 4

Pressure Rod Lowered To Engage Pins

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 7 of 9

Revision A

6. While continuing to apply downward force to the Pressure Rod, begin turning the Knob in a

clockwise direction to start lifting the connector off the board.

•Once the connector is free of the backplane, it is not necessary to continue to turn the

knob and you can proceed to step 7 below.

7. Lift the “AHR” tool upward from the backplane with the extracted connector, as shown in

Figure 5 below.

Figure 5

AHR Tool With Extracted Connector

8. To remove the connector from the tool, rotate the Knob counter-clockwise until the Pressure

Rod bottoms out on the slot and a 2-3mm gap is present between the Knob and the Nylon

Washer. Holding onto the Jack-Frame with one hand, use the other hand to press downward

on the Knob to release clamping pressure with the Comb Plates. Remove the extracted

connector from the tool by rocking the connector end-to-end and side-to-side.

•The tool was designed to extract stitched headers with as few pins remaining in

the backplane as possible. Fully inserting the tool into the connector to engage

more pins is not required and may require additional rocking of the connector to

remove the extracted connector from the tool and.

•Stray pins will often remain on the backplane and will require individual

extraction with pliers.

Figure 6

Stray Pins Following Connector Extraction

9. Following the removal of the remaining pins, verify that the backplane holes are clear of debris

and, utilizing the correct insertion block assembly, insert a new Airmax Stitched Header.

•Never attempt to re-install a previously removed connector or individual pins.

PDS: Rev :A STATUS:Released Printed: Oct 13, 2011

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FCI USA LLC Manual Part No. 10118041-9090

Issued: (2011/08/12) Page 8 of 9

Revision A

MAINTENANCE

It is recommended that each operator of the tool be made aware of, and responsible for, the following

maintenance steps:

1. It is good practice to keep the hand tool clear of extracted pins.

2. Remove dust, moisture, and other contaminants with a clean brush, or soft, lint free cloth.

3. Do not use any abrasive materials that could damage the tool.

4. Never use air to blow away debris.

5. If an instance should occur of an extracted terminal remaining in the tooling, minimize the use

any instruments to remove the terminal as this can damage the various tooling components.

6. When tool is not in use, store in a clean, dry area.

Notes

1. This tool should only be used to extract the associated Airmax Stitched Header specified within

this manual.

2. FCI does not repair hand tools. With consideration that the tooling covered in the parts list is

mainly for reference, most of the listed items are available as replacement parts. Verify the part

number and revision level of your tool before ordering replacement components.

3. Protect the tool from being dropped onto hard surfaces as this could damage the tool if left in

the fully extended condition.

•A good practice is to retract the Plate Guide inside the jack-frame when the tool is not in

use or prior to storage.

4. Check for damaged parts. Before further use of the tool, determine that it would operate

properly and perform its intended function – check for alignment of moving parts, binding of

moving parts, breakage of parts, mounting, and any other conditions that may affect the

operation.

PDS: Rev :A STATUS:Released Printed: Oct 13, 2011

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