558211-3 - Tyco Electronics

Application Specification

114-6016

Modular Plug Connectors

LOC B

of 12

2008 Tyco Electronics Corporation, Harrisburg, PA

All International Rights Reserved

TE logo and Tyco Electronics are trademarks.

*Trademark. Other products, logos, and company names used are the property of their respective owners.

TOOLING ASSISTANCE CENTER 1-800-722-1111

PRODUCT INFORMATION 1-800-522-6752 This controlled document is subject to change.

For latest revision and Regional Customer Service,

visit our website at

www.tycoelectronics.com

(Standard and Small Conductor)

07 OCT 08 Rev G

All numerical values are in metric units [with U.S. customary units in brackets]. Dimensions are in millimeters [and

inches]. Unless otherwise specified, dimensions have a tolerance of +0.13 [+.005] and angles have a tolerance of +2

Figures and illustrations are for identification only and are not drawn to scale.

1. INTRODUCTION

This specification covers the requirement for application of standard and small conductor Modular Plug

Connectors for voice and data applications. The modular plugs are available in standard and small conductor,

unshielded or shielded, with 2, 4, 6, 8, or 10 terminals on 1.02 [.040] centerline spacing. These modular plugs

are also available in line and keyed housing styles. The modular plugs contain solid wire terminals or stranded

wire terminals; each terminal design optimized for its specific application.

The modular plugs accept flat oval (“silver satin”) cable or round jacketed, unshielded or shielded cable with 2,

4, 6, 8, or 10 conductors. Specific wire approved is tinsel wire size 28 AWG, 7– and 19–strand wire, stranded

wire sizes 28 through 24 AWG, and solid wire sizes 26 through 24 AWG. Wire size 24 AWG is approved

provided the insulated conductor outside diameter is less than or equal to 0.99 [.039].

Each modular plug features two internal strain reliefs to protect the modular plug–to–cable and

terminal–to–conductor interface from damage when subjected to pulling or bending forces—the primary strain

relief grips the jacket and the secondary strain relief acts on the conductors. These modular plugs are

terminated using the insulation piercing technique. The modular plugs are available in loose piece for

terminating with manual or pneumatically–powered tools.

When corresponding with personnel, use the terminology provided in this specification to facilitate your

inquiries for information. Basic terms and features of this product are provided in Figure 1.

Figure 1

Shield

Locking Latch

Shielded Modular PlugUnshielded Modular Plug

Cable

Opening

Terminal 1

Housing

Primary (Jacket)

Strain Relief

Secondary (Conductor)

Strain Relief

Housing

Terminal 1

Solid Wire Terminal

Termination Stranded Wire Terminal

Termination

NOTE

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Modular Plug Connectors (Standard and Small Conductor)

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2. REFERENCE MATERIAL

2.1. Revision Summary

Updated document to corporate requirements

Removed offset modular plugs

Removed strip form modular plugs

Removed obsolete Hand Tool 231649–1 and Modular Plug Adapter 318510–1

Removed AMP–O–LECTRIC* Model “G” terminating machines (and applicators) and 626 pneumatic

tooling assemblies (and straight action tool holder assemblies)

2.2. Customer Assistance

Reference Product Base Part Number 554739 and Product Code 1423 are representative of Modular Plug

Connectors (standard and small conductor). Use of these numbers will identify the product line and expedite

your inquiries through a service network established to help you obtain product and tooling information. Such

information can be obtained through a local Representative or, after purchase, by calling PRODUCT

INFORMATION at the number at the bottom of page 1.

2.3. Drawings

Customer Drawings for product part numbers are available from the service network. If there is a conflict

between the information contained in the Customer Drawings and this specification or with any other technical

documentation supplied, call PRODUCT INFORMATION at the number at the bottom of page 1.

2.4. Specifications

Product Specification 108–1163 provides product performance and test information.

Application Specification 114–6053 provides product description and application requirements for high

performance modular plug connectors, and 114–2048 (through hole) and 114–6040 (surface mount) provides

product description and application requirements for mating modular jack assemblies.

2.5. Instructional Material

Instruction Sheets (408–series) provide product assembly instructions or tooling setup and operation

procedures and Customer Manuals (409–series) provide machine setup and operating procedures. Documents

available which pertain to this product are:

408–3151 Modular Plug Connector Chordal Hand Tool 231648–1

(For 2–, 4–, and 6–Position Line Modular Plugs)

408–4093 PRO–CRIMPER* III Hand Tool Assembly 58560–1 (For 10–Position Modular Plugs)

408–4167 PRO–CRIMPER III Hand Tool Assembly 224928–1 (For External Strain Relief Application)

408–4389 Crimp Height Gage 904170–1

408–9743 Terminating Modules 856196–[ ] for Use with Modular Plug Dual Terminators 1320840–[ ]

408–9767 Modular Plug Hand Tools (Premium Grade) 231652–[ ]

408–9919 Modular Plug Single Terminators 354711–[ ] and Tooling Kits 354714–[ ]

409–10010 Modular Plug Dual Terminators 1320840–[ ]

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Tyco Electronics Corporation

3. REQUIREMENTS

3.1. Material

Modular plug housings are made of flame retardant polycarbonate rated Underwriter Laboratories, Inc. (UL) 94

V–0. The terminals are made of phosphor bronze under–plated with nickel; terminal area is plated with gold,

and insulation piercing tips are plated with gold flash. Shields are made of brass plated with bright tin–lead and

under–plated with copper. External strain reliefs are made of brass plated with tin and under–plated with

copper.

3.2. Storage

A. Ultraviolet Light

Prolonged exposure to ultraviolet light may deteriorate the chemical composition used in the modular plug

material.

B. Shelf Life

The modular plugs should remain in the shipping containers until ready for use to prevent plating damage

to the terminals. The modular plugs should be used on a first in, first out basis to avoid storage

contamination that could adversely affect performance.

3.3. Chemical Exposure

Do not store modular plugs near any chemical listed below as they may cause stress corrosion cracking in

the terminals.

Alkalies Ammonia Citrates Phosphates Citrates Sulfur Compounds

Amines Carbonates Nitrites Sulfur Nitrites Tartrates

3.4. Cable Selection

Standard modular plugs accept cable with insulated conductor outside diameter range of 0.74 through 0.99

[.029 through .039].

Small conductor modular plugs accept cable with insulated conductor outside diameter range of 0.74 through

0.86 [.029 through .034]. These modular plug housings are tinted blue to differentiate from standard modular

plugs.

Not all standard modular plugs have a small conductor modular plug equivalent.

A. 2- and 4-Conductor Cable

Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through

.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be

exceeded

Conductor types: tinsel (28 AWG only), 28 through 26 AWG 7–strand wire, or 26 through 24 AWG solid

wire

Cable jacket insulation types:

1. Flat oval

Height: 2.29+0.25 [.090+.010]

Width for 2–conductor: 3.81+0.13 [.150+.005]

Width for 4–conductor: 4.83+0.25 [.190+.010]

2. Round

Maximum outside diameter: 2.54 [.100]

NOTE

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Modular Plug Connectors (Standard and Small Conductor)

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B. 6-Conductor Cable

Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through

.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be

exceeded.

Conductor types: unshielded: 7–strand wire for sizes 28 through 26 AWG or solid wire for sizes 26 through

24 AWG, shielded: 7–strand wire, 5 conductors for sizes 28 through 26 AWG and 1 drain wire sizes 24

through 22 AWG or 6–conductor cable with drain wire

Cable jacket insulation types:

1. Unshielded flat oval

Height: 2.29+0.25 [.090+.010]

Width: 6.60+0.25 [.260+.010]

2. Shielded flat oval

Height: 2.79 [.110] max

Width: 6.86 [.270] max

3. Round: 4.57 [.180] max outside diameter

Shield type: metalized polyester foil

C. 8- and 10-Conductor Cable

Conductor sizes: 28, 26, or 24 AWG with insulation outside diameter of 0.74 through 0.99 [.029 through

.039]. For the modular plug to accept the conductor, the maximum diameter (0.99 [.039]) must not be

exceeded.

Conductor types: unshielded: 7–strand wire for sizes 28 through 24 AWG or solid wire for sizes 26 through

24 AWG, shielded: 7–strand wire, 7 conductors for sizes 28 through 24 AWG and 1 drain wire sizes 24

through 22 AWG or 8–conductor cable with drain wire

Cable jacket insulation types:

1. Unshielded flat oval

Height: 2.29+0.25 [.090+.010]

Width: 8.89+0.25 [.350+.010]

2. Shielded flat oval

Height: 2.79 [.110] max

Width: 9.02 [.355] max

3. Round: 5.46 [.215] max outside diameter

Shield type: metalized polyester foil only, braided shield should not be used

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Tyco Electronics Corporation

3.5. Cable Preparation

Proper strip length is necessary to properly insert the cable into the modular plugs. The strip length for the

cable and specific cable and modular plug combinations is shown in Figure 2.

Reasonable care must be taken not to nick or cut the cable conductor insulation during the stripping operation.

Typical Round CableTypical Flat Oval Cable

Strip Length

Insulated

Conductors

Unshielded Shielded Unshielded Shielded

MODULAR PLUG CABLE

TYPE

POSITION/TERMINAL

FLAT OVAL ROUND

STRIP LENGTH

TYPE

POSITION/TERMINAL

Stranded Solid Stranded Solid

STRIP LENGTH

Unshielded, Handset 4/4

n n

Ċ Ċ 6.35-7.14

[.25-.28]

Unshielded Keyed

8/8

n n n

Ċ12.7-14.3

Unshielded

Keyed

10/10 Ċ Ċ

Ċ[.25-.56]

6/2

Ċ Ċ Ċ

635 714

6/4

n n

Ċ Ċ 6.35-7.14

[.25

.28]

Unshielded Line

6/6

n n n

[

28]

Unshielded

Line

8/4

Ċ Ċ Ċ

12 7 14 3

8/8

n n n n

12.7-14.3

[.50

.56]

10/10 Ċ Ċ

[

56]

Unshielded Small Conductor (Blue)

6/4, 6/6, 8/8

n n

Ċ Ċ 6.35-7.14

[.25-.28]

Unshielded

Small Conductor (Blue)

10/10

n n n

Ċ6.35-7.14

[.25-.28]

Unshielded, Long Body 6/6

n n n

Ċ 14.3 [.56]

Shielded, Line 8/8

n n

14.3 [.56]

Shielded, Long Body 6/6

Ċ 14.3 [.56]

Shielded Line Keyed

8/4

Ċ Ċ Ċ

14 3 [ 56]

Shielded

Line

Keyed

8/8 Ċ Ċ

56]

Shielded, Small Conductor (Blue)

8/8 Ċ Ċ

n n

14.3 [.56]

Figure 2

For conductor outside insulation diameter range of 0.74 through 0.86 [.029 through .034]

NOTE

114-6016

Modular Plug Connectors (Standard and Small Conductor)

Rev

of 12 Tyco Electronics Corporation

A. Flat Oval Shielded Cable

This cable must be prepared according to the following. Refer to Figure 3:

1. Insert a blade tip between the conductors and shield. Slit the jacket and shield 14.29 [9/16] back from

the end along one edge of the cable. Repeat on the opposite cable edge.

2. Pull the slit ends away from the conductors. Separate the shield from the slit ends of the jacket.

3. Cut off the slit ends of the jacket 14.29 [9/16] from the end of the conductors. Care should be taken

not to cut shield ends.

4. Fold each shield end back on itself to approximately one–half of its length.

5. Bend each folded shield back on top of the jacket. The shield must extend approximately 9.52 [3/8]

back on the jacket and the exposed conductors must be approximately 14.29 [9/16] in length.

6. If the drain wire is to be terminated within the modular plug, insert the drain wire into the wire circuit of

the modular plug, and terminate according to the instructions packaged with the applicable tooling.

If the drain wire is to be terminated to the modular plug shield, bend the drain wire back tightly across

the center of the cable shield on the side of the cable that will face the locking latch side of the modular

plug when the cable is inserted. Cut the drain wire to the same length as the cable shield.

Figure 3

Flat Oval Shielded

Cable

Jacket

Shield

Drain Wire

14.29 [9/16] Cut

Note:

Not to Scale

14.29 [9/16] Slit

Conductors

Fold Shield

14.29 [9/16] Length of

Exposed Conductors

9.52 [3/8] Shield

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Modular Plug Connectors (Standard and Small Conductor)

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Tyco Electronics Corporation

B. Round Shielded Cable

This cable must be prepared according to the following. Refer to Figure 4:

1. Insert a blade tip between the shield and jacket. Slit the jacket 15.88 [5/8] back from the end.

2. Pull the jacket away from the shield, and fold it back over the cable. Cut off the slit portion of the

jacket 15.88 [5/8] from the end of the conductors. Care shall be taken not to cut the shield.

3. Find the overlap seam in the shield, and pull the shield away from the conductors while being careful

not to damage the shield.

4. Fold the shield back over the cable.

5. Trim the shield to approximately 9.52 [3/8] in length. Form the shield smoothly around the outside of

the cable. Untwist the conductors and orient them in desired sequence. Trim the conductors evenly to

14.29 [9/16] in length.

6. If the drain wire is to be terminated within the modular plug, insert the drain wire into the wire circuit of

the modular plug, and terminate according to the instructions packaged with the applicable tooling.

If the drain wire is to be terminated to the modular plug shield, bend the drain wire back tightly across

the center of the cable shield on the side of the cable that will face the locking latch side of the modular

plug when the cable is inserted. Cut the drain wire to the same length as the cable shield.

Figure 4

9.52 [3/8]

Trim Shield

Round Shielded

Cable

Note:

Not to Scale

Jacket

Shield

2Conductors

15.88 [5/8]

Drain Wire

Fold Shield

14.29 [9/16]

Trim Conductors

3.6. Termination Requirements

A. Conductor Location

Conductors must be fully inserted into the proper wire circuit of the modular plug to ensure that the

terminals pierce a sufficient wire area. It is preferred that all conductors be visually bottomed against the

end of the wire circuits. If individual conductors are not completely inserted after termination, they must be

inserted at least past the terminal and into the reference zone to ensure a proper electrical interface. See

Figure 5.

114-6016

Modular Plug Connectors (Standard and Small Conductor)

Rev

of 12 Tyco Electronics Corporation

B. Crimp Height

The crimp height shall be measured from the top of the terminals to the bottom of the housing (not

including locking tab) and must be within the dimension provided in Figure 5.

All terminals must be at approximately the same height. A crimp height gage is available for measuring modular plug

crimp height (refer to Section 5 for part number and description).

C. Internal Strain Reliefs

The primary strain relief must be fully engaged on the cable jacket, and the secondary strain relief must be

fully engaged on the cable conductors. Both strain reliefs must be fully engaged to isolate the termination

area from external forces applied to the cable. It is acceptable for the primary strain relief to cut into the

jacket as long as the conductor insulation is not compromised. See Figure 5.

For unshielded modular plug, the primary and secondary strain reliefs can be visually inspected through the side of the

housing.

Figure 5

0.00-0.64 [.000-.025]

Reference Zone

(Conductor Location)

6.02+0.13 [.237+.005]

Crimp Height (Requirement

Per FCC Part 68, Subpart F)

Secondary Strain Relief

Engaging Conductors Primary Strain Relief

Engaging Cable Jacket

Section X-X

Conductors Against

End of Wire Circuits

(Preferred Conductor

Location)

Terminal

Primary

Strain Relief

Secondary

Strain Relief

NOTE

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Tyco Electronics Corporation

3.7. Ancillary Items

A. External Strain Relief

The external strain relief can only be used with 8- and 10-position (shielded and unshielded) modular plugs.

The external strain relief provides a secure grip (360

wrap) on the cable jacket for extraordinary strain

relief on the cable and a redundant low impedance ground path to equipment. For shielded modular plugs,

the external strain relief also provides a secure grip on the foil shield and a chassis ground through the

modular plug shield. If a boot is used, an external strain relief containing a retention hole for securing the

boot is available (the boot must be installed after the external strain relief with retention hole).

Using the boot and the external strain relief with retention hole will provide optimum strain relief performance.

Assembly of the external strain relief onto the modular plug must meet the requirements shown in

Figure 6.

Figure 6

External

Strain Relief

External Strain Relief Seated

Flat Against Modular Plug

Support Barrel Evenly

Crimped and Firm

Around Cable

Support Barrel Does

Not Cut into Cable

External Strain Relief

with Retention Hole (for

Securing Boot)

B. Boot

A boot is used to prevent the cable from kinking and bending too sharp at the modular plug cable opening.

The boot is available with or without a hood. The hooded boot also prevents the modular plug locking latch

from snagging other locking latches or cables.

The boots are available to fit maximum cable insulation diameters of 5.33 [.210] for unshielded modular

plugs and 5.72 [.225] for shielded modular plugs. The maximum cable diameter is marked on the inside of

each boot. The boots are colored to provide a color–coded cable configuration to ensure appropriate

connections. The boot must be installed, small diameter end first, onto the cable before the stripping

procedure. Boots are made of elastomer polyolefin. Refer to Figure 7.

Figure 7

Cable Insulation Diameter

Within Maximum Cable

Diameter Marked Inside Boot

Hood of Boot Over

Modular Plug Locking Latch

Hooded BootBoot

Notch in Boot Facing

Modular Plug Locking Latch

NOTE

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Modular Plug Connectors (Standard and Small Conductor)

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of 12 Tyco Electronics Corporation

3.8. Mating

The modular plug must be inserted into the mating jack until it bottoms. When fully inserted, the modular plug

locking tab will engage the jack housing and prevent the connectors from separating. The connectors will not

unmate unless the modular plug locking latch is fully depressed. After mating, there will be a small amount of

axial movement (travel) between the mated modular plug and jack, and with some combinations, depending on

tolerance variations between original equipment manufacturers (OEM), could be up to 0.76 [.030].

3.9. Repair

These modular plugs cannot be repaired; damaged modular plugs must be removed and discarded. The cable

must be cut from the modular plug and re–terminated onto a new modular plug.

4. QUALIFICATION

Standard and small conductor Modular Plug Connectors are Component Recognized by Underwriters

Laboratories Inc. (UL) in File E81956 (DUXR2), and Certified by CSA International in File LR 7189A.

5. TOOLING

Tooling part numbers and instructional material packaged with the tooling are shown in Figure 8.

5.1. Hand Tools

The premium grade modular plug hand tool terminates these modular plugs to all types of cable indicated in

this document. The tool also cuts and strips unshielded flat oval cable. This tool is designed for field

application, installation, and repair.

PRO–CRIMPER III hand tool assemblies are “commercial” grade tools designed primarily for field installation

or repair. There is a tool availabe to terminate 10–position modular plugs and a tool to apply the external strain

relief.

The chordal hand tool is an “economy” grade tool used to strip the cable and terminate the modular plugs. This

tool is designed for occasional use and low–volume application.

5.2. Terminators

The terminators are pneumatically powered, bench–mounted tools controlled by a foot valve to terminate

modular plugs to create a cable assembly. Terminating modules fit interchangeably into the dual terminators.

During termination, the dual terminators test the assembly for electrical circuit continuity. The single terminators

require a specific tooling kit to terminate one modular plug style and does not provide testing. These tools

provide for high–volume applications.

5.3. Crimp Height Gage

The crimp height gage is used to measure the crimp height of the terminated modular plug. The crimp height

gage is used for 2–, 4–, 6–, 8–, and 10–position modular plugs. Take note that the gage cannot be used for

4–position handset modular modular plugs. The gage consists of a connector nest and a GO/NO–GO spanner.

114-6016

Modular Plug Connectors (Standard and Small Conductor)

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Tyco Electronics Corporation

Figure 8

Modular Plug Single Terminators

354711-[ ] and Tooling Kits 354714-[ ]

(408-9919)

Modular Plug Hand Tools

(Premium Grade) 231652-[ ]

with Die Sets 853400-[ ]

(408-9767)

Modular Plug Dual Terminators

1320840-[ ] (409-10010) Terminating Modules

856196-[ ] (408-9743)

PRO-CRIMPER III Hand Tool

Assembly 224928-1 with

Die Assembly 224928-2

(For External Strain Relief Application)

(408-4167)

PRO-CRIMPER III Hand Tool

Assembly 58560-1 with Die

Assembly 58560-2

(For 10-Position Modular Plugs)

(408-4093)

Modular Plug Connector Chordal

Hand Tool 231648-[ ] (For 2-, 4-,

and 6-Position Line Modular Plugs)

(408-3151)

Crimp Height Gage

904170-1 (408-4389)

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of 12 Tyco Electronics Corporation

6. VISUAL AID

The illustration below shows a typical application of standard and small conductor Modular Plug Connectors.

This illustration should be used by production personnel to ensure a correctly applied product. Applications

which DO NOT appear correct should be inspected using the information in the preceding pages of this

specification and in the instructional material shipped with the product or tooling.

FIGURE 9. VISUAL AID

ALL CONDUCTORS MUST BE

BOTTOMED AGAINST END

OF MODULAR PLUG WIRE

CIRCUITS

ALL TERMINALS HAVE THE

PROPER CRIMP HEIGHT AND

MUST BE AT APPROXIMATELY

THE SAME HEIGHT

EXTERNAL STRAIN RELIEF

MUST BE SEATED FLAT

AGAINST MODULAR PLUG

SUPPORT BARREL MUST BE

EVENLY CRIMPED AND FIRM

AROUND CABLE

MODULAR PLUG WITH

EXTERNAL STRAIN RELIEF

SUPPORT BARREL MUST

NOT CUT INTO CABLE

MODULAR PLUG WITH

BOOT

THERE MUST BE NO NICKS

OR CUTS IN CABLE

THERE MUST BE NO

DAMAGE TO HOUSING

OR LOCKING LATCH

PRIMARY STRAIN RELIEF MUST

ENGAGE CABLE JACKET

CABLE INSULATION DIAMETER

MUST BE WITHIN MAXIMUM

CABLE DIAMETER MARKED

INSIDE BOOT

HOOD OF BOOT MUST

BE OVER MODULAR

PLUG LOCKING LATCH

THERE MUST BE NO

DAMAGE TO BOOT

OR MODULAR PLUG

LOCKING LATCH

NOTCH IN BOOT MUST

FACE MODULAR PLUG

LOCKING LATCH

SECONDARY STRAIN RELIEF MUST

ENGAGE CABLE CONDUCTORS