5520251-4 - Tyco Electronics

Product

Specification

108-1163

12Jan10 Rev E

Modular Plugs, Thru-Hole and Surface Mount Jacks, Data

and Telephone, PCB Mounted

Harrisburg, PA

All International Rights Reserved.

* Trademark

| Indicates change

For latest revision, visit our website at www.tycoelectronics.com\documents.

For Regional Customer Service, visit our website at www.tycoelectronics.com

1 of 7

LOC B

1. SCOPE

1.1. Content

This specification covers the performance, tests and quality requirements for the Tyco Electronics

Modular Telephone Plugs and Jacks designed for Printed Circuit Board (PCB) mounting.|

1.2. Qualification

When tests are performed on the subject product line, procedures specified in Figure 1 shall be used.

All inspections shall be performed using the applicable inspection plan and product drawing.

1.3. Qualification Test Results

Successful qualification testing on the subject product line was completed on 19May89. The

Qualification Test Report number for this testing is 501-91. This documentation is on file at and

available from Engineering Practices and Standards (EPS).

2. APPLICABLE DOCUMENTS

The following documents form a part of this specification to the extent specified herein. Unless

otherwise specified, the latest edition of the document applies. In the event of conflict between the

requirements of this specification and the product drawing, the product drawing shall take precedence.

In the event of conflict between the requirements of this specification and the referenced documents,

this specification shall take precedence.

2.1. Tyco Electronics Specifications

!109 Series: Test Specifications as indicated in Figure 1

!114-2048: Application Specification (Modular Jacks)|

!114-6016: Application Specification (Modular Plug Connectors (Standard and Small Conductor))|

!114-6040: Application Specification (Modular Jack Surface Mount Printed Circuit (PC) Board|

Assemblies)|

!114-6053: Application Specification (High Performance Modular Plug Connectors)|

!501-91: Qualification Test Report (Modular Plugs, Thru-Hole and Surface Mount Jacks, Data and|

Telephone, PCB Mounted)|

2.2. Industry Document|

EIA-364: Electrical Connector/Socket Test Procedures Including Environmental Classifications|

2.3. Reference Documents|

!108-1163-2: Product Specification (High Performance Modular Plugs & Jacks, PCB Mounted)|

!109-197: Test Specification (AMP Test Specifications vs EIA and IEC Test Methods)

!EIA/TIA 568-A: Commercial Building Telecommunications Cabling Standard

!FCC Rules for Registration of Telephone Equipment Part 68, Subpart F, Connectors

!REA Bulletin 345-81, PE-76: Specification for Modular Telephone Set Hardware

108-1163

Rev E 2 of 7

3. REQUIREMENTS

3.1. Design and Construction

Product shall be of the design, construction and physical dimensions specified on the applicable|

Product Drawing.

3.2. Materials

Materials used in the construction of this product shall be as specified on the applicable product

drawing.

3.3. Ratings

!Current, per pin: 1.5 amperes alternating current maximum at 25°C derated to 0.2 amperes|

maximum at 70°C ambient

!Derating Curve:

!Voltage: 150 volts AC maximum

!Temperature: -40 to 70°C

!Shielding Effectiveness: 20 dB minimum reduction from 30 to 400 MHZ

108-1163

Rev E 3 of 7

3.4. Performance and Test Description

Product shall be designed to meet the electrical, mechanical and environmental performance|

requirements specified in Figure 1.

3.5. Test Requirements and Procedures Summary

Test Description Requirement Procedure

Examination of product. Meets requirements of product

drawing and Application

Specifications 114-6016, 114-2048.

114-6040, and 114-6053.

EIA-364-18.

Visual, dimensional and functional

per applicable inspection plan.

ELECTRICAL

Termination resistance, dry circuit. ΔR of 30 milliohms. EIA-364-23.

Subject mated plug and jack to 50

millivolts open circuit at 100

milliamperes maximum.

See Figure 3.

Termination resistance, rated

current.

ΔR of 30 milliohms. EIA-364-6.

Measure potential drop of mated

plug and jack while carrying 1.5

amperes current.

See Figure 3.

Insulation resistance. 500 megohms minimum. EIA-364-21.

Test between adjacent contacts of

mated plug and jack.

Dielectric withstanding voltage. One minute hold. EIA-364-20, Condition I.

1000 volts AC (rms) 60 Hz.

Test between adjacent contacts of

mated plug and jack.

Temperature rise vs current. 30°C maximum temperature rise at

1.5 amperes.

EIA-364-70, Method 1.

Subject mated plug and jack to

temperature rise at rated current.

Current cycling. No evidence of physical damage. AMP Spec 109-51, Condition B,

Method 2.

Subject mated plug and jack to 500

cycles at 125% of rated current for

15 minutes ON and 15 minutes

OFF.

Shielding effectiveness, thru-hole

jacks only.

Frequency: 30 to 400 MHZ.

Reduction: 20 dB minimum.

AMP Spec 109-90.

Measure radiated response from

unshielded mated jack and plug

terminated with unshielded cable

while conductors are excited

between 30 and 400 MHZ. Repeat

procedure using shielded jack

mated with shielded plug terminated

with aluminum/MYLAR shielded

cable. The difference in response is

shielding effectiveness in dB.

Figure 1 (continued)

108-1163

Test Description Requirement Procedure

Rev E 4 of 7

Surge. No evidence of physical damage. Subject mated plug and jack

adjacent contacts to 5 surges of

each polarity at 1 minute intervals.

Pulse to have 10/1000 microsecond

shape and 1000 volt peak.

MECHANICAL

Vibration. No discontinuities greater than 1

microsecond.

Shall remain mated and show no

evidence of physical damage.

EIA-364-28, Test Condition I.

Subject mated plug and jack

mounted on PCB to sinusoidal

vibration for 15 minutes in each of 3

mutually perpendicular axis.

Durability. No evidence of physical damage. EIA-364-9.

Subject plug and jack to 750 mating

and unmating cycles at the rate of

500 cycles per hour with latch

inoperative.

Mating and unmating forces. Five pounds maximum for

unshielded plug and jack.

Eight pounds maximum for shielded

plug and jack.

EIA-364-13.

Measure force required to mate

plug and jack. Measure force

required to unmate plug and jack

with latch depressed.

Plug retention in jack. Plug shall not dislodge from jack. EIA-364-98.

Apply axial load of 20 pounds to

plug housing at a rate of 0.5 inch

per minute with plug mated in jack

and latch engaged.

Pull. Plug shall remain mated with no

evidence of damage.

Load cable in mated plug with a 17

pound pull in axial direction, rotate

plug housing 45 degrees from cable

axis, remove load.

See Figure 4.

Jack retention to PCB. Jack shall not dislodge from PCB.

One pound minimum before flow

soldering.

Ten pounds minimum after flow

soldering.

Apply perpendicular load at a rate of

2 inches per minute to the jack

mounted on a 0.062 inch thick PCB.

See Figure 4.

ENVIRONMENTAL

Thermal shock. No evidence of physical damage. EIA-364-32.

Subject mated plug and jack to 25

cycles between -40 and 60°C.

High humidity/temperature cycling. No evidence of physical damage. AMP Spec 109-76-2.

Subject mated plug and jack to 10

humidity/temperature cycles

between 4 and 60°C at 95% RH.

Figure 1 (end)

108-1163

Rev E 5 of 7

3.6. Connector Tests and Sequences

Test or Examination

Test Group (a)

123456789

Test Sequence (b)

Examination of product 111111111

Termination resistance, dry circuit 2,4 2,4 4,6 2,6 2,4

Termination resistance, rated current 2,5

Insulation resistance 4 5 5

Dielectric withstanding voltage 2 4

Temperature rise vs current 3

Current cycling 4

Shielding effectiveness 2

Surge 3

Vibration 3

Durability 5

Mating force 2

Unmating force 3

Plug retention in jack 2

Pull 3

Jack retention to PCB 3

Thermal shock 3

High humidity/temperature cycling 3

(a) See paragraph 4.1.A.

NOTE (b) Numbers indicate sequence in which tests are performed.

Figure 2

108-1163

Rev E 6 of 7

4. QUALITY ASSURANCE PROVISIONS

4.1. Qualification Testing

A. Sample Selection

Modular plug and jack test samples shall be selected at random from current production lots. They

shall be prepared for testing in accordance with current Application Specifications and Instruction

Sheets.

B. Test Sequence

Qualification testing shall be conducted as specified in Figure 2.

4.2. Requalification Testing

If changes significantly affecting form, fit, or function are made to the product or to the manufacturing

process, product assurance shall coordinate requalification testing, consisting of all or part of the

original testing sequence as determined by development/product, quality, and reliability engineering.

4.3. Acceptance

Acceptance is based on verification that the product meets the requirements of Figure 1. Failures

attributed to equipment, test setup, or operator deficiencies shall not disqualify the product. When

product failure occurs, corrective action shall be taken and samples resubmitted for qualification.

Testing to confirm corrective action is required before resubmittal.

4.4. Quality Conformance Inspection

The applicable quality inspection plan will specify the sampling acceptable quality level to be used.

Dimensional and functional requirements shall be in accordance with the applicable product drawing

and this specification.

108-1163

Rev E 7 of 7

Millivolt drop (resistance) due to the 6 inch wire length shall be subtracted from all readings.

NOTE

Figure 3

Termination Resistance Measurement Points

Figure 4

Plug and Jack Retention Forces