Qualifi cation Tes t
Report 501-553
08Jan08 Rev E
NETCONNECT* SL Series Jacks and Category 6 Plugs
©2008 Tyco Electronics Corpo ration
Harrisburg, PA
All International Rights Rese rve d
* Trademark
| Indicates change 1 of 7
LOC B
1. INTRODUCTION
1.1. Purpose
Testi ng was perfor med on NET C ONNECT* SL Series Jacks and Category 6 Plugs to determine t heir
confor mance to the requirements of Product Specifi cation 108-1990 Revisi on A.
1.2. Scope
This report covers the electrical , mechani cal, and environmental performance of NETC ONNECT SL
Series Jacks and Category 6 Plugs. T esting w as performed at the Engineering Assurance Product
Testi ng Laboratory between 01Oct01 and 01Nov02.
1.3. Conclusion
The NETCONNECT SL Series Jacks and Category 6 Pl ugs listed in paragraph 1.5 conformed to t he
el ectrical, mechanical, and environmental performance requirements of Product Speci fication 108-1990
Revision A.
1.4. Product Description
These assemblies are designed for installation into various outlet plates, surface mount boxes, panels,
and other similar type fittings. Jacks incorporate IDC t ermi nals for termi nating both shielded or
unshi elded twi sted pair communications cable. Jacks will accommodate 22 - 24 AWG solid and 24-26
AWG stranded conductors. The maximum conductor i nsulation diameter is 1.45 mm [.057 in]. For large
OD conductor s 1.27 to 1.45 mm an external strain relief must be used. The plugs accommodate
Categor y 6 cable and shielded or unshielded twi sted pair cable with 23 - 24 AWG solid, or 24 - 26 AWG
str anded conductors. The maximum conductor insul ation diameter is 1.00 mm [.039 in] with a cable
jacket diameter between 4.7 and 7.0 mm [.185 and .276 i n].
1.5. Test Speci mens
Test speci mens were r epresentative of normal production lots. Specimens identified wi th the foll owing
part numbers were used for test:
Part
Number Description Test Group Total
123456a6b6c7a7b7c8a8b8c9a9b9c10a10b10c11
1375191 Category 5e jack 5555555 55 55 55 55 75
1375192 Category 3 jack 5555525
1375188 Shielded Category 6 55
1375202 Category 6 plug 5555555555 50
558530 HP plug 5555525
641337 6 position plug 5555525
1375202 Shielded plug 55
Fi gure 1
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1.6 Envir onmental Conditions
Unl ess otherwise stated, the following environmental condit ions prevailed during test ing:
!
Temperature: 15 to 35
/
C
!
Relative Humidity: 25 to 75%
1.7. Qual ification Test Sequence
Test or Examination Test Group (a)
1234567891011
Test Sequence (b)
Examination of product 1,5 1,7 1,8 1,4 1,5 1,5 1,5 1,6 1,5 1,8 1,5
Contact resistance 2,4 2,6 2,7 2,4 2,4 2,5 2,7
Insulation resistance 3,6
Voltage proof 2,4
Vibration, jack-plug and IDC-wire interface 3
Mechanical shock, jack-plug interface 3 4
Dura bility, jack-plug interface (6 posit ion plug) 3
Dura bility, jack-plug interface 4
Plug insertion force, jack-plug interface 2 2
Plug withdrawal force, jack-plug interface 3 3
Plug retention in jack, jack-plug interface 4
Termination tensile strength, horizontal, IDC-wire interface 2
Termination tensile strength, vertical, IDC-wire interface 3
Dura bilit y, repeated, IDC-wire inte rfa ce 3(c)
Thermal sho ck, IDC-wire interface 4 4
Thermal shock, jack-plug interface 5
Humidity/temperature cycling, IDC-wire interface 5 5
Humidity, steady state, jack-plug interface 364
Stress relaxation, IDC-wire interfac e 3
Mixed flowing gas, jack-plug interface 3(d)
(a) See paragraph 1.5.
NOTE
(b) Numbers indicate sequence in which tests are performed.
(c) Perform 100 cycles (t erminations) on jack IDC’s before thermal shock, 33 additional cycles
(t ermi nations) on jack IDC’s after 50 temperat ure cycles of thermal shock, 33 cycles
(t ermi nations) on jack IDC’s after 7 days of humidity/temperat ure cycling, and 34 cycles
(t ermi nations) after 21 days of humidity/temperature cycling.
|
(d) Precondition jack interface with 40 durabili ty cycles.
Fi gure 2
2. SUMMARY OF TESTING
2.1. Initi al Exami nation of Product - All Test Groups
Al l speci mens submitted for testing were represent ative of normal production lots. Product Assur ance
i ssued a Certificate of Confor mance. Where specified, speci mens were visually examined and no
evidence of physical damage detri mental to product performance was observed.
2.2. Contact Resistance - Test Groups 1, 2, 3, 5, 6, 8 and 10
Al l termination resistance measurements taken at 100 milliamperes maximum and 20 millivolts
maximum open circuit voltage were less than 20 milliohms
)
R after testing.
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2.3. Insulati on Resistance - Test Group 3
Al l i nsulation resistance measurements w ere greater than 500 megohms mini mum.
2.4. Vol tage Proof - Test Group 9
No di electric breakdow n or flashover occurred.
2.5. Vi bration - Test Group 10
No di scontinuities greater than 1 microsecond wer e detected during vibration testing. Following vibration
test ing, no cracks, breaks, or loose parts w ere visibl e on the specimens.
2.6. Mechanical Shock - Test Gr oups 6 and 10
No di scontinuities greater than 1 microsecond wer e detected during mechanical shock testing. Fol lowing
mechanical shock testing, no cracks, breaks, or loose parts on the specimens were visible.
2.7. Durability, Jack-plug Interface (6 position plug) - Test Group 8
No physical damage occurred to t he specimens as a result of mating and unmating the specimens 200
times.
2.8. Durability, Jack-plug Interface - Test Group 8
No physical damage occurred to t he specimens as a result of mating and unmating the specimens 750
times.
2.9. Pl ug Insertion Force, Jack-plug Inter face - Test Groups 7 and 11
Al l i nsertion forces were less than 5 pounds for unshielded and 8 pounds for shielded specimens.
2.10. Pl ug Withdrawal Force, Jack-plug Interface - Test Group 7 and 11
Al l withdrawal forces were less than 5 pounds for unshielded and 8 pounds for shielded specimens.
2.11. Pl ug Retention in Jack, Jack-plug Inter face - Test Group 7
Al l contacts wit hstood a force of 20 pounds f or 5 seconds wi thout dislodging from the housing.
2.12. Ter mination Tensile Strengt h, Horizontal - Test Group 4
Al l tensile values were great er than 14.0 pounds for 22 AWG solid wire, 12. 0 pounds for 23 AWG sol id
wire, 9.5 pounds for 24 AWG solid wire, 7. 5 pounds for 24 AWG stranded wir e and 4.6 pounds for 26
AWG str anded wir e.
2.13. Ter mination Tensile Strengt h, Vertical - Test Group 4
Al l tensile values were great er than 1.5 pounds for 22 AWG solid wire, 1. 0 pound for 23 AWG sol id wire,
1.0 pound f or 24 AWG solid wire, 1.5 pounds for 24 AWG stranded wi re and 1.9 pounds for 26 AWG
str anded wir e.
2.14. Durability, Repeated, IDC-wire Inter face - Test Group 2
No physical damage occurred to t he specimens as a result of terminating and re-terminating the
speci mens 200 times.
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2.15. Ther mal Shock, IDC-wir e Interface - Test Groups 2 and 3
No evidence of physical damage was visible as a result of exposure to thermal shock.
2.16. Ther mal Shock, Jack-plug Interface - Test Gr oup 10
No evidence of physical damage was visible as a result of exposure to thermal shock.
2.17. Humidity/ Temperat ure Cycl ing, IDC-wire Interf ace - Test Groups 2 and 3
No evidence of physical damage was visible as a result of exposure to humi dity/temperature cycling.
2.18. Humidity, Steady State, Jack-plug Interface - Test Groups 9, 10 and 11
No evidence of physical damage was visible as a result of exposure to humi dity-temperature cycling.
2.19. Stress Relaxation, IDC-wire Interface - Test Group 1
No evidence of physical damage was visible as a result of exposure to temperature life.
2.20. Mixed Flowi ng Gas - Test Gr oup 5
No evidence of physical damage was visible as a result of exposure to the pollutants of mixed flowing
gas.
2.21. Fi nal Examination of Product - All T est Groups
Speci mens were visuall y examined and no evidence of physical damage detrimental to product
perf ormance was observed.
3. TEST METHODS
3.1. Examination of Product
A Cert ification of Confor mance w as issued stating that all specimens in this test package have been
produced, inspected, and accepted as confor ming to product drawing requirements, and made using
the same core manufacturing processes and technologies as production parts.
3.2. Contact Resistance
Terminat ion resistance measurements at low l evel current were made using a 4 termi nal measuring
technique (Fi gure 3). T he test current was maintained at 100 milliamperes maximum with a 20 millivolt
maximum open circuit voltage.
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Fi gure 3
Typical Termi nation Resistance Measur ement Points
3.3. Insulati on Resistance
Insulati on resistance was measured between adjacent contacts of mated speci mens. A test voltage of
100 volts DC was applied for 1 minute before the resistance was measured.
3.4. Vol tage Proof
A test potential of 1000 volt s AC was applied between the adjacent contacts of mated specimens. This
potent ial was applied for 1 mi nute and then returned to z ero.
3.5. Vi bration, Jack-plug Interface and I DC-wire Interface
The specimens were subjected to a si mple harmonic motion havi ng amplitude of 0.028 inch double
amplitude (maximum total excursion). The vi bration frequency was varied unif orml y between t he
approxi mate limits of 10 to 55 Hz. The entire frequency range of 10 to 55 Hz and return to 10 Hz w as
repeat ed 5 times and traversed at a rate of 1 octave per mi nute. The motion was appli ed in each of the
3 mutual ly per pendicular axes. T he test specimens w ere rigidly mounted t o the vibrating surface while
the cable ends were not secured t o any support (cables wer e to short to suppor t). T he test specimens
were moni tored for discontinui ties of 1 microsecond or greater using an energi zing cur rent of 100
milliamperes.
3.6. Mechanical Shock, Jack-plug Interface
The parameters of this test condi tion are a half-sine waveform w ith an acceleration ampl itude of 30
gravity uni ts (g's peak) and a durat ion of 11 milliseconds. Three shocks in each di rection were appl ied
al ong the 3 mutually perpendicular axes of the test speci men, for a total of 18 shocks. The test
speci mens were r igidly mounted to the shock surface w hile the cable ends w ere not secured to any
support (cables w ere to short to support). The t est specimens wer e monitored for di scontinuities of 1
micr osecond or greater using an energizi ng current of 100 milliamperes.
3.7. Durability, Jack-plug Interface (6 position plug)
Speci mens were mated and unmated for 200 cycl es at a maximum rate of 500 cycles per hour.
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3.8. Durability, jack-plug Interface
Speci mens were mated and unmated for 750 cycl es at a maximum rate of 500 cycles per hour.
3.9. Pl ug Insertion Force, Jack-plug Inter face
The force r equired to mate individual specimens was measured using a tensile/ compression device wi th
a fr ee floating fixture and a rate of tr avel of .5 inch per mi nute.
3.10. Pl ug Withdrawal Force, Jack-plug Interface
The force r equired to unmate individual specimens was measured using a tensile/ compression device
with a free floati ng fixture and a rate of tr avel of .5 inch per mi nute.
3.11. Pl ug Retention in Jack, Jack-plug Inter face
An axial load of 20 pounds was appli ed to mated connector assembl ies in a direction that would cause
the connect or lacking latches to di sengage.
3.12. Ter mination Tensile Strengt h, Horizontal
The force load was applied to each specimen using a tensile/compression device wit h the rate of travel
at . 5 inch per minute.
3.13. Ter mination Tensile Strengt h, Vertical
The force load was applied to each specimen using a tensile/compression device wit h the rate of travel
at . 5 inch per minute.
3.14. Durability, Repeated, IDC-wire Inter face
Wires were terminated and re-terminated on jack's IDC for 200 cycles using impact tool part number
1375308-1 set on low impact setting.
3.15. Ther mal Shock, IDC-wir e Interface
Mated specimens wer e subjected to 100 cy cles of thermal shock wit h each cycle consisting of 30
minut e dwells at -40 and 70
/
C. The tr ansition between temperatures was an average of 3 minutes.
3.16. Ther mal Shock, Jack-plug Interface
Mated specimens wer e subjected to 25 cy cles of thermal shock wit h each cycle consisting of 30 mi nute
dwells at -40 and 70
/
C. The tr ansition between temperatures was less than 1 minut e.
3.17. Humidity/Temperature Cycling, IDC- wir e Interface
Mated specimens wer e exposed to 21 cycles of humidity/ temperature cycl ing. Each cycle lasted 24
hours and consisted of cy cling the temperature between 25 and 65
/
C twice while maintaining high
humidity. During 5 of the first 7 cycles, the specimens wer e exposed to a cold shock at -10
/
C for 3 hours
(Figure 4).
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Fi gure 4
Typical Humi dity /Temperature Cycling Profile
3.18. Humidity, Steady State, Jack-plug Interface
Mated specimens wer e subjected to a relative humidity of 95% and a temperature of 55
/
C for a period
of 10 day s.
3.19. Stress Relaxation, IDC-wire Interface
Mated specimens wer e exposed to a temperature of 70
/
C for 500 hours.
3.20. Mixed Flowi ng Gas, Jack-plug Interface
Mated specimens wer e exposed for 4 day s to a mi xed flowing gas I EC 68-2-60, 1995-12, Method 2
exposure. Ex posure is defined as a temperature of 30
/
C and a relati ve humidity of 70% with the
pol lutants of Cl2 at 10 ppb, NO2 at 200 ppb, and H2S at 10 ppb. Specimens were pr econditioned wi th 40
cycles of durability.
3.21. Fi nal Examination of Product
Speci mens were visuall y examined and no evidence of physical damage detrimental to product
perf ormance was observed.
HUMIDITY-TEMPERATURE
CYCLING
-15
-10
-5
0
5
10
15
20
25
30
35
40
45
50
55
60
65
70
75
80
85
0 2 4 6 8 1012141618202224
Tim e (hours)
Temperature (C)
{ 90/95% R H }{80/90}{ 90/95% R H }(80/90}{ 90/95% RH }
