Modular Plug Connectors (Standard and Small Conductor)

Modular Plug Connectors (Standard and Small Conductor) Applcaton Specfcaton 114-6016 04 APR 11 All numercal values are n metrc unts [wth U.S. customary unts n brackets]. Dmensons are n mllmeters [and nches]. Unless otherwse specfed, dmensons have a tolerance of ±0.13 [±.005] and angles have a tolerance of ± 2. Fgures and llustratons are for dentfcaton only and are not drawn to scale. 1. INTRODUCTION Ths specfcaton covers the requrement for applcaton of standard and small conductor Modular Plug Connectors for voce and data applcatons. The modular plugs are avalable n standard and small conductor, unshelded or shelded, wth 2, 4, 6, 8, or 10 termnals on 1.02 [.040] centerlne spacng. These modular plugs are also avalable n lne and keyed housng styles. The modular plugs contan sold wre termnals or stranded wre termnals; each termnal desgn optmzed for ts specfc desgn. The modular plugs accept flat oval ("slver satn") cable or round jacketed, unshelded or shelded cable wth 2, 4, 6, 8, or 10 conductors. Specfc wre approved s tnsel wre sze 28 AWG, 7- and 19-strand wre, stranded wre szes 28 through 24 AWG, and sold wre szes 26 through 24 AWG. Wre sze 24 AWG s approved provded the nsulated conductor outsde dameter s less than or equal to 0.99 [.039]. Each modular plug features two nternal stran relefs to protect the modular plug-to-cable and termnal-toconductor nterface from damage when subjected to pullng or bendng forces-the prmary stran relef grps the jacket and the secondary stran relef acts on the conductors. These modular plugs are termnated usng the nsulaton percng technque. The modular plugs are avalable n loose pece for termnatng wth manual or pneumatcally-powered tools. When correspondng wth personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. When correspondng wth personnel, use the termnology provded n ths specfcaton to facltate your nqures for nformaton. Basc terms and features of ths product are provded n Fgure 1. Unshelded Modular Plug Shelded Modular Plug Termnal 1 Secondary (Conductor) Stran Relef Housng Termnal 1 Housng Prmary (Jacket) Stran Relef Sheld Cable Openng Lockng Latch Sold Wre Termnal Termnaton Sold Wre Termnal Termnaton Fgure 1 2011 Tyco Electroncs Corporaton, a TE Connectvty Ltd. Company All Rghts Reserved *Trademark TOOLING ASSISTANCE CENTER 1-800-722-1111 PRODUCT INFORMATION 1-800-522-6752 Ths controlled document s subject to change. For latest revson and Regonal Customer Servce, vst our webste at www.te.com TE Connectvty, TE connectvty (logo), and TE (logo) are trademarks. Other logos, product and/or Company names may be trademarks of ther respectve owners. 1 of 12 LOC B

2. REFERENCE MATERIAL 2.1. Revson Summary Snce the prevous release of ths document, the new company logo has been appled. 2.2. Customer Assstance Reference Product Base Part Number 554739 and Product Code 1423 are representatve of Modular Plug Connectors (standard and small conductor). Use of these numbers wll dentfy the product lne and expedte your nqures through a servce network establshed to help you obtan product and toolng nformaton. Such nformaton can be obtaned through a local Representatve or, after purchase, by callng PRODUCT INFORMATION at the number at the bottom of page 1. 2.3. Drawngs Customer Drawngs for product part numbers are avalable from the servce network. If there s a conflct between the nformaton contaned n the Customer Drawngs and ths specfcaton or wth any other techncal documentaton suppled, call PRODUCT INFORMATION at the number at the bottom of page 1. 2.4. Specfcatons Product Specfcaton 108-1163 provdes product performance and test nformaton. Applcaton Specfcaton 114-6053 provdes product descrpton and applcaton requrements for hgh performance modular plug connectors, and 114-2048 (through hole) and 114-6040 (surface mount) provdes product descrpton and applcaton requrements for matng modular jack assembles. 2.5. Instructonal Materal Instructon Sheets (408-seres) provde product assembly nstructons or toolng setup and operaton procedures and Customer Manuals (409-seres) provde machne setup and operatng procedures. Documents avalable whch pertan to ths product are: 408-3151 Modular Plug Connector Chordal Hand Tool 231648-1 (For 2-, 4-, and 6-Poston Lne Modular Plugs) 408-4093 PRO-CRIMPER* III Hand Tool Assembly 58560-1 (For 10-Poston Modular Plugs) 408-4167 PRO-CRIMPER III Hand Tool Assembly 224928-1 (For External Stran Relef Applcaton) 408-4389 Crmp Heght Gage 904170-1 408-9743 Termnatng Modules 856196-[ ] for Use wth Modular Plug Dual Termnators 1320840-[ ] 408-9767 Modular Plug Hand Tools (Premum Grade) 231652-[ ] 408-9919 Modular Plug Sngle Termnators 354711-[ ] and Toolng Kts 354714-[ ] 409-10010 Modular Plug Dual Termnators 1320840-[ ] 3. REQUIREMENTS 3.1. Materal Modular plug housngs are made of flame retardant polycarbonate rated Underwrter Laboratores, Inc. (UL) 94 V-0. The termnals are made of phosphor bronze under-plated wth nckel; termnal area s plated wth gold, and nsulaton percng tps are plated wth gold flash. Shelds are made of brass plated wth brght tn-lead and under-plated wth copper. External stran relefs are made of brass plated wth tn and under-plated wth copper. 3.2. Storage A. Ultravolet Lght Prolonged exposure to ultravolet lght may deterorate the chemcal composton used n the modular plug materal. B. Shelf Lfe The modular plugs should reman n the shppng contaners untl ready for use to prevent platng damage to the termnals. The modular plugs should be used on a frst n, frst out bass to avod storage contamnaton that could adversely affect performance. 2 of 12

3.3. Chemcal Exposure Do not store modular plugs near any chemcal lsted below as they may cause stress corroson crackng n the termnals. Alkales Ammona Ctrates Phosphates Ctrates Sulfur Compounds Amnes Carbonates Ntrtes Sulfur Ntrtes Tartrates 3.4. Cable Selecton Standard modular plugs accept cable wth nsulated conductor outsde dameter range of 0.74 through 0.99 [.029 through.039]. Small conductor modular plugs accept cable wth nsulated conductor outsde dameter range of 0.74 through 0.86 [.029 through.034]. These modular plug housngs are tnted blue to dfferentate from standard modular plugs. Not all standard modular plugs have a small conductor modular plug equvalent. A. 2- and 4-Conductor Cable Conductor szes: 28, 26, or 24 AWG wth nsulaton outsde dameter of 0.74 through 0.99 [.029 through.039]. For the modular plug to accept the conductor, the maxmum dameter (0.99 [.039]) must not be exceeded Conductor types: tnsel (28 AWG only), 28 through 26 AWG 7-strand wre, or 26 through 24 AWG sold wre 1.Cable jacket nsulaton types: Flat oval Heght: 2.29+0.25 [.090+.010] Wdth for 2-conductor: 3.81+0.13 [.150+.005] Wdth for 4-conductor: 4.83+0.25 [.190+.010] 2. Round Maxmum outsde dameter: 2.54 [.100] B. 6-Conductor Cable Conductor szes: 28, 26, or 24 AWG wth nsulaton outsde dameter of 0.74 through 0.99 [.029 through.039]. For the modular plug to accept the conductor, the maxmum dameter (0.99 [.039]) must not be exceeded. Conductor types: unshelded: 7-strand wre for szes 28 through 26 AWG or sold wre for szes 26 through 24 AWG, shelded: 7-strand wre, 5 conductors for szes 28 through 26 AWG and 1 dran wre szes 24 through 22 AWG or 6-conductor cable wth dran wre Cable jacket nsulaton types: 1.Unshelded flat oval Heght: 2.29+0.25 [.090+.010] Wdth: 6.60+0.25 [.260+.010] 2.Shelded flat oval Heght: 2.79 [.110] max Wdth: 6.86 [.270] max 3.Round: 4.57 [.180] max outsde dameter Sheld type: metalzed polyester fol 3 of 12

C. 8- and 10-Conductor Cable Conductor szes: 28, 26, or 24 AWG wth nsulaton outsde dameter of 0.74 through 0.99 [.029 through.039]. For the modular plug to accept the conductor, the maxmum dameter (0.99 [.039]) must not be exceeded. Conductor types: unshelded: 7-strand wre for szes 28 through 24 AWG or sold wre for szes 26 through 24 AWG, shelded: 7-strand wre, 7 conductors for szes 28 through 24 AWG and 1 dran wre szes 24 through 22 AWG or 8-conductor cable wth dran wre Cable jacket nsulaton types: 1.Unshelded flat oval Heght: 2.29+0.25 [.090+.010] Wdth: 8.89+0.25 [.350+.010] 2.Shelded flat oval Heght: 2.79 [.110] max Wdth: 9.02 [.355] max 3.Round: 5.46 [.215] max outsde dameter Sheld type: metalzed polyester fol only, braded sheld should not be used 3.5. Cable Preparaton Proper strp length s necessary to properly nsert the cable nto the modular plugs. The strp length for the cable and specfc cable and modular plug combnatons s shown n Fgure 2. Reasonable care must be taken not to nck or cut the cable conductor nsulaton durng the strppng operaton. A. Flat Oval Shelded Cable Ths cable must be prepared accordng to the followng. Refer to Fgure 3: 1.Insert a blade tp between the conductors and sheld. Slt the jacket and sheld 14.29 [9/16] back from the end along one edge of the cable. Repeat on the opposte cable edge. 2..Pull the slt ends away from the conductors. Separate the sheld from the slt ends of the jacket. 3.Cut off the slt ends of the jacket 14.29 [9/16] from the end of the conductors. Care should be taken not to cut sheld ends. 4.Fold each sheld end back on tself to approxmately one-half of ts length. 5.Bend each folded sheld back on top of the jacket. The sheld must extend approxmately 9.52 [3/8] back on the jacket and the exposed conductors must be approxmately 14.29 [9/16] n length. 6.If the dran wre s to be termnated wthn the modular plug, nsert the dran wre nto the wre crcut of the modular plug, and termnate accordng to the nstructons packaged wth the applcable toolng. If the dran wre s to be termnated to the modular plug sheld, bend the dran wre back tghtly across the center of the cable sheld on the sde of the cable that wll face the lockng latch sde of the modular plug when the cable s nserted. Cut the dran wre to the same length as the cable sheld. 4 of 12

Typcal Flat Oval Cable Typcal Round Cable Unshelded Shelded Unshelded Shelded Insulated Conductors Strp Length Strp Length MODULAR PLUG CABLE TYPE POSITION/ TERMINAL FLAT OVAL ROUND Stranded Sold Stranded Sold STRIP LENGTH Unshelded, Handset 4/4 n n -- -- 6.35-7.14 [.25 -.28] Unshelded, Keyed Unshelded, Lne Unshelded Small Conductor (Blue) 8/8 n n n -- 10/10 -- -- n -- 6/2 n -- -- -- 6/4 n n -- -- 6/6 n n n -- 8/4 n -- -- -- 8/8 n n n n 10/10 -- -- n -- 6/4, 6/6, 8/8 n n n n 10/10 n n n -- 12.7-14.3 [.25 -.56 6.35-7.14 [.25 -.28] 12.7 14.3 [.50 -.56] 6.35-7.14[. [.25 -.28] 6.35-7.14[. [.25 -.28] Unshelded, Long Body 6/6 n n n -- 14.3 [.56] Shelded, Lne 8/8 n -- n n 14.3 [.56] Shelded, Long Body 6/6 n n n -- 14.3 [.56] Shelded, Lne, Keyed 8/4 n -- -- -- 8/8 -- -- n -- 14.3 [.56] Shelded, Small Conductor (Blue) 8/8 -- -- n n 14.3 [.56] For conductor outsde nsulaton dameter range of 0.74 through 0.86 [.029 through.034] Fgure 2 5 of 12

Flat Oval Shelded Cable Fold Sheld 14.9 [9/16] Slt Jacket Sheld Conductors 14.29 [9/16] Cut 14.29 [9/16] Length of Exposed Conductors Note: Not to Scale Dran Wre B. Round Shelded Cable Fgure 3 Ths cable must be prepared accordng to the followng. Refer to Fgure 4: 1) Insert a blade tp between the sheld and jacket. Slt the jacket 15.88 [5/8] back from the end. 2) Pull the jacket away from the sheld, and fold t back over the cable. Cut off the slt porton of the jacket 15.88 [5/8] from the end of the conductors. Care shall be taken not to cut the sheld. 3) Fnd the overlap seam n the sheld, and pull the sheld away from the conductors whle beng careful not to damage the sheld. 4) Fold the sheld back over the cable. 5) Trm the sheld to approxmately 9.52 [3/8] n length. Form the sheld smoothly around the outsde of the cable. Untwst the conductors and orent them n desred sequence. Trm the conductors evenly to 14.29 [9/16] n length. 6) If the dran wre s to be termnated wthn the modular plug, nsert the dran wre nto the wre crcut of the modular plug, and termnate accordng to the nstructons packaged wth the applcable toolng. 6 of 12

If the dran wre s to be termnated to the modular plug sheld, bend the dran wre back tghtly across the center of the cable sheld on the sde of the cable that wll face the lockng latch sde of the modular plug when the cable s nserted. Cut the dran wre to the same length as the cable sheld. Round Shelded Cable Fold Sheld Sheld Jacket Conductorss 9.52 [3/8] Trm Sheld 14.29 [9/16] Trm Conductors 15.88 [5/8] Note: Not to Scale 3.6. Termnaton Requrements Fgure 4 A. Conductor Locaton Conductors must be fully nserted nto the proper wre crcut of the modular plug to ensure that the termnals perce a suffcent wre area. It s preferred that all conductors be vsually bottomed aganst the end of the wre crcuts. If ndvdual conductors are not completely nserted after termnaton, they must be nserted at least past the termnal and nto the reference zone to ensure a proper electrcal nterface. See Fgure 5. B. Crmp Heght The crmp heght shall be measured from the top of the termnals to the bottom of the housng (not ncludng lockng tab) and must be wthn the dmenson provded n Fgure 5. All termnals must be at approxmately the same heght. A crmp heght gage s avalable for measurng modular plug crmp heght (refer to Secton 5 for part number and descrpton). C. Internal Stran Relefs The prmary stran relef must be fully engaged on the cable jacket, and the secondary stran relef must be fully engaged on the cable conductors. Both stran relefs must be fully engaged to solate the termnaton area from external forces appled to the cable. It s acceptable for the prmary stran relef to cut nto the jacket as long as the conductor nsulaton s not compromsed. See Fgure 5. 7 of 12

For unshelded modular plug, the prmary and secondary stran relefs can be vsually nspected through the sde of the housng. Secondary Stran Relef Prmary Stran Relef Secton x-x 6.02 ± 0.13 [.237 ±.005] Crmp Heght (Requrement Per FCC Part 68, Subpart F) Termnal Secondary Stran Relef Engagng Conductors Prmary Stran Relef Engagng Cable Jacket Conductors Aganst End of Wre Crcuts (Preferred Conductor Locaton) 0.00-0.64 [.000 -.025] Reference Zone (Conductor Locaton) 3.7. Ancllary Items Fgure 5 A. External Stran Relef The external stran relef can only be used wth 8- and 10-poston (shelded and unshelded) modular plugs. The external stran relef provdes a secure grp (360º wrap) on the cable jacket for extraordnary stran relef on the cable and a redundant low mpedance ground path to equpment. For shelded modular plugs, the external stran relef also provdes a secure grp on the fol sheld and a chasss ground through the modular plug sheld. If a boot s used, an external stran relef contanng a retenton hole for securng the boot s avalable (the boot must be nstalled after the external stran relef wth retenton hole). Usng the boot and the external stran relef wth retenton hole wll provde optmum stran relef performance. Assembly of the external stran relef onto the modular plug must meet the requrements shown n Fgure 6. 8 of 12

External Stran Relef External Stran Relef Seated Flat Aganst Modular Plug Support Barrel Evenly Crmped and Frm Around the Cable External Stran Relef wth Retenton Hole (for Securng the Boot) Support Barrel Does Not Cut Into Cable B. Boot Fgure 6 A boot s used to prevent the cable from knkng and bendng too sharp at the modular plug cable openng. The boot s avalable wth or wthout a hood. The hooded boot also prevents the modular plug lockng latch from snaggng other lockng latches or cables. The boots are avalable to ft maxmum cable nsulaton dameters of 5.33 [.210] for unshelded modular plugs and 5.72 [.225] for shelded modular plugs. The maxmum cable dameter s marked on the nsde of each boot. The boots are colored to provde a color-coded cable confguraton to ensure approprate connectons. The boot must be nstalled, small dameter end frst, onto the cable before the strppng procedure. Boots are made of elastomer polyolefn. Refer to Fgure 7. Boot Notch n Boot Facng Modular Plug Lockng Latch Hooded Boot Hood or Boot Over Modular Plug Lockng Latch Cable Insulaton Dameter Wthn Maxmum Cable Dameter Marked Insde Boot 3.8. Matng Fgure 7 The modular plug must be nserted nto the matng jack untl t bottoms. When fully nserted, the modular plug lockng tab wll engage the jack housng and prevent the connectors from separatng. The connectors wll not unmate unless the modular plug lockng latch s fully depressed. After matng, there wll be a small amount of axal movement (travel) between the mated modular plug and jack, and wth some combnatons, dependng on tolerance varatons between orgnal equpment manufacturers (OEM), could be up to 0.76 [.030]. 3.9. Repar These modular plugs cannot be repared; damaged modular plugs must be removed and dscarded. The cable must be cut from the modular plug and re-termnated onto a new modular plug. 9 of 12

4. QUALIFICATION Standard and small conductor Modular Plug Connectors are Component Recognzed by Underwrters Laboratores Inc. (UL) n Fle E81956 (DUXR2), and Certfed by CSA Internatonal n Fle LR 7189A. 5. TOOLING Toolng part numbers and nstructonal materal packaged wth the toolng are shown n Fgure 8. 5.1. Hand Tools The premum grade modular plug hand tool termnates these modular plugs to all types of cable ndcated n ths document. The tool also cuts and strps unshelded flat oval cable. Ths tool s desgned for feld applcaton, nstallaton, and repar. PRO-CRIMPER III hand tool assembles are "commercal" grade tools desgned prmarly for feld nstallaton or repar. There s a tool avalabe to termnate 10-poston modular plugs and a tool to apply the external stran relef. The chordal hand tool s an "economy" grade tool used to strp the cable and termnate the modular plugs. Ths tool s desgned for occasonal use and low-volume applcaton. 5.2. Termnators The termnators are pneumatcally powered, bench-mounted tools controlled by a foot valve to termnate modular plugs to create a cable assembly. Termnatng modules ft nterchangeably nto the dual termnators. Durng termnaton, the dual termnators test the assembly for electrcal crcut contnuty. The sngle termnators requre a specfc toolng kt to termnate one modular plug style and does not provde testng. These tools provde for hgh-volume applcatons. 5.3. Crmp Heght Gage The crmp heght gage s used to measure the crmp heght of the termnated modular plug. The crmp heght gage s used for 2-, 4-, 6-, 8-, and 10-poston modular plugs. Take note that the gage cannot be used for 4-poston handset modular modular plugs. The gage conssts of a connector nest and a GO/NO-GO spanner. 10 of 12

Fgure 8 11 of 12

6. VISUAL AIDVISUAL AID The llustraton below shows a typcal applcaton of standard and small conductor Modular Plug Connectors. Ths llustraton should be used by producton personnel to ensure a correctly appled product. Applcatons whch DO NOT appear correct should be nspected usng the nformaton n the precedng pages of ths specfcaton and n the nstructonal materal shpped wth the product or toolng. FIGURE 9. VISUAL AID 12 of 12