Stewart Connector
Product Specification
PR022-01
Revision C0 3/2/2016
Modular Products
Stewart Connector
11118 Susquehanna Trail South
Glen Rock, Pa. 17327-9199
Ph: (717) 235-7512 Fax: (717) 235-4675
http://www.stewartconnector.com
Page 1 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
1.0
Objective
This document establishes the performance requirements and outlines qualification tests for shielded and
unshielded modular connectors produced by Stewart Connector. These products are intended to be
soldered onto a printed circuit board or terminated onto a cable and mated to a compatible Stewart
Connector modular product.
2.0
Scope
This specification is applicable to shielded and unshielded modular products.
3.0
General
This document is comprised of the following sections (specifications subject to change without notice):
Paragraph
Title
1.0
2.0
3.0
Table 1
4.0
Table 2
5.0
6.0
Table 3
Figure 1
7.0
Table 4
8.0
9.0
Table 5
Figure 2
Figure 3
Figure 4
Table 6
Table 7
Table 8
10.0
Table 9
Table 10
Table 11
Figure 5
Table 12
Table 13
Table 14
Table 15
11.0
Table 16
Table 17
Table 18
Objective
Scope
General
Qualification Test Matrix
Applicable Documents
IEC Modular Plug and Jack Standards
General Requirements
Soldering Process Requirements
Wave Solder
IR Reflow Profile
Quality Assurance Provisions
Inspection Conditions
Requalification of Products
Electrical Requirements
LLCR
Bulk Contact Interface LLCR Measurement
Bulk Shield Interface LLCR Measurement
LLCR Measurement Configuration
Insulation Resistance
DWV (Adjacent Contacts)
DWV (Contacts to Shield)
Mechanical Requirements
Mechanical Durability
Gauging – Go Gauges
Mating / Unmating Force
Discontinuity Configuration
Mechanical Shock
Sinusoidal Vibration
Random Vibration
Rotational Test
Environmental Conditions
Temperature Life
Thermal Shock
Temperature / Humidity
Modular Connectors
http://www.stewartconnector.com
Table 1
Qualification Testing Matrix
Page 2 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
Qualification
Testing Matrix
Test
Examination of Product
Low Level Contact Resistance
Temperature Rise vs. Current
Durability
Gaging
PCB Insertion Force
Mating / Unmating Force
Discontinuity
Latch Strength
Mechanical Shock
Vibration (Sinusoidal)
Vibration (Random)
Temperature Life
Thermal Shock
Temperature/Humidity
Insulation Resistance
D. W. V. (Adj. Contacts) (2)
D. W. V. (Contacts-Shield) (1,2)
RJ-11 Insertion (4)
Rotational Test
Para.
5.5
9.1
9.2
10.1
10.2
10.3
10.4
10.5
10.6
10.7
10.8
10.9
11.1
11.2
11.3
9.3
9.4
9.5
10.10
10.11
Note:
Modular Connectors
http://www.stewartconnector.com
1
2
3
1,5
2,4
3
1,5
2,4
1,7
Test Groups
5
6
Testing Sequence (3)
1,7
1,5
1,6
2,6
2,4
2,4
4
7
8 (4)
9
1,8
2,4
1,5
2,4
1,3
3
2
3
4
5
6
5
3
4
3
3
5
3
5
6
7
3
2
1
2
3
4
Only Applies to Shielded Product
DWV stands for Dielectric Withstand Voltage
Numbers indicate sequence in which tests are performed.
Test Group 8 Applies to RJ-45 style jacks only
Page 3 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
4.0
Applicable Documents
4.1
Stewart Connector Specifications:
4.1.1 Product Drawings
4.1.2 Customer Drawings
4.1.3 Test Specifications
4.2
Other Standards and Specifications (Applicable in Part):
4.2.1 UL94V-0 Flammability
4.2.2 EIA-364
4.2.3 EIA/TIA-568
4.2.4 EIA/TIA-570
4.2.5 IEC 60603-7
4.2.6 TIA 1096
4.2.7 IEEE 802.3
Table 2
IEC Modular Plug and Jack Standards
Category
Type
Standard
Base
UTP
IEC 60603-7
Specification
ScTP
IEC 60603-7-1
Category 5e
UTP
IEC 60603-7-2
Category 5e
ScTP
IEC 60603-7-3
Category 6
UTP
IEC 60603-7-4
Category 6
ScTP
IEC 60603-7-5
UTP – Unshielded Twisted Pair
ScTP – Screened Twisted Pair
Additional specifications and standards may be referenced as applicable. The latest revisions of
the above specifications available at the date of issue of this specification are used unless
otherwise indicated.
Modular Connectors
http://www.stewartconnector.com
Page 4 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
5.0
General Requirements
5.1
Qualification:
Connectors furnished under this specification shall be capable of meeting the qualification test
requirements specified herein.
5.2
Material:
5.3
5.2.1
5.2.2
5.2.3
Plastic Housings: UL94V-0
Contacts: Copper Alloy
Shield: Copper Alloy
5.3.1
5.3.2
5.3.3
5.3.4
Contacts: Gold Selectively Plated
Contacts: Nickel Plated All Over
Reference Customer Drawing for Contact Solder Tails
Shield: Tin or Nickel Plated All Over
Finish:
5.4
Design and Construction:
Connectors shall be of the design, construction and physical dimensions as specified on the
applicable product drawing and TIA 1096. In case of conflict between this specification and
product drawings, the drawings shall take precedence. 50 inch (1.27 m) gold plated
connectors compliant with TIA 1096 specifications.
5.5
Examination of Product:
Connectors shall meet all specified dimensions of product drawings and internal workmanship
standards. There shall be no evidence of cracking, chipping, contamination or loose parts when
inspected, without magnification, to the unaided eye.
5.6
Operating and Storage Temperature Range: -40°C to 85°C
5.7
Ratings:
5.7.1 Current:
5.7.2 Voltage:
1.5 amperes maximum at 25C
150 VAC maximum
5.8
Minimum Number of Mating/Unmating Operations:
5.8.1 Performance Level 1: 750 Cycles
5.8.2 Performance Level 2: 2500 Cycles
5.9
Minimum Number of Cable Re-Terminations:
5.9.1 Refer to application drawings
Modular Connectors
http://www.stewartconnector.com
Page 5 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
Soldering Process Requirements
6.1
Wave Solder:
Modular connectors are capable of withstanding wave solder temperatures without any functional
deterioration. See Table 3 below:
Table 3
Wave Solder Process Profile
Low-Temp Products
High-Temp Products
6.2
Maximum
Temperature
428F (220C)
500F (260C)
Maximum Temperature
Exposure Time
10 Seconds
10 Seconds
IR Reflow Solder:
High-temperature modular connectors are capable of withstanding non-focused infrared (IR)
reflow and equivalents at up to 500F (260C) without any functional deterioration. The
modular jacks shall be exposed to profiles as specified in Figure 1 below:
IR Reflow Profile
300
260
Temperature (Degrees C)
6.0
250
200
150
100
50
0
0
40
80
120
160
200
240
280
320
360 380
Time (seconds)
FIGURE 1
* Note: IR Profile may not apply to products with LEDs or light pipes. Please consult factory
for specifics.
Modular Connectors
http://www.stewartconnector.com
Page 6 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
7.0
Quality Assurance Provisions
7.1
Equipment Calibration:
All test equipment and inspection facilities used in the performance of any test shall be
maintained and calibrated in accordance with Stewart Connector Operating Procedures and/or
other applicable specifications.
7.2
Inspection Conditions:
Unless otherwise specified, all inspections shall be performed under the conditions noted.
See Table 2 below:
Table 4
Inspection Conditions
Temperature
(±5 ºC)
25
7.3
Relative
Humidity
(%)
30 to 50
Barometric
Pressure
Local Ambient
Sample Quantity and Description:
The test samples required for groups 1 through 9 in Table 1 shall be chosen to comprise a group
that consists of 80 contacts, on 10 ports, on two connectors minimum. For samples with multiple
contact designs, there shall be 20 examples minimum of each individual contact design.
Test group 8 is only applicable to 8 and 10 position RJ-45 style jacks.
The test samples required for group 10 in Table 1 shall be chosen to comprise a group that
consists of 16 total contacts on 2 connectors minimum.
7.4
Acceptance:
7.4.1 All samples tested in accordance with this product specification shall meet the stated
requirements.
7.4.2
8.0
Failures attributed to equipment, test set-up, sample preparation problems, contaminants
or operator error, should not disqualify the product. Corrective action will be taken and
samples re-submitted for qualification.
Requalification of Products
8.1
Requalification Testing
If changes are made to the product, design or manufacturing process after initial product
qualification that are judged by the management of Stewart Connector to materially affect the
product form, fit or function, then new product samples shall be subject to full or partial
requalification testing.
Modular Connectors
http://www.stewartconnector.com
Page 7 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
9.0
Electrical Requirements
9.1
Low Level Contact Resistance (Board Mounted Product):
LLCR should be measured (mated with a Stewart Connector plug) in accordance
with EIA-364-23 with a test current of 100 mA and a maximum open circuit voltage of 20
mVDC (dry circuit test). See Table 5 below:
Table 5
Low Level Contact Resistance
Contacts
Shield Interface **
Final
Initial
Final
(m)
(m)
(m)
20
40
20
All values listed are maximum values.
* 100 m Initial LLCR Includes Bulk
** Shield Interface LLCR Not Applicable to Unshielded Connectors
Initial
(m)
100 *
Low Level Contact Resistance (LLCR) is measured on a mated Plug and Jack.
Measurements are generally performed before and after environmental exposure or
mechanical conditioning. Bulk LLCR is measured between a mated Plug conductor and
Jack printed wiring board (PWB) pin. Bulk resistance consists of the following four (4)
components. Refer to Figure 2 below.
Contacts RBulk = Rab+Rbc+Rcd+Rde
(1)
(2)
(3)
(4)
(Rab) Plug Conductor Resistance
(Rbc) Plug Blade/Conductor Contact Resistance
(Rcd) Plug Blade/Jack Wire Contact Resistance
(Rde) Jack Wire Resistance
d
a
c
b
e
Bulk Low Level Contact Resistance
(LLCR)
FIGURE 2
Modular Connectors
http://www.stewartconnector.com
Page 8 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
9.1
Low Level Contact Resistance: (Cont.)
Shield Interface RBulk = Rab+Rbc+Rcd+Rde
(1)
(2)
(3)
(4)
(Rab) Jack Shield Resistance
(Rbc) Jack Shield/Plug Shield Contact Resistance
(Rcd) Plug Shield/Cable Shield Contact Resistance
(Rde) Cable Shield Resistance
b1
c1
d
c2
a
e
b2
Shield Interface Bulk Low Level Contact Resistance
(LLCR)
FIGURE 3
Typical Bulk contact resistance of a mated plug and jack can range between 20 to 50 m.
Stewart Connector product specification requirement is a bulk contact resistance change
after conditioning. In most cases, the maximum allowable change in bulk contact resistance
after environmental conditioning is 20 m.
LLCR measurements are conducted utilizing a four (4) wire dry circuit test method.
Implementation consists of a 100 mA DC current source with a maximum open circuit
voltage of 20 mV. Measurements are performed using low current and voltage levels to
preserve oxides and films that may form during environmental conditioning.
In practice, Jacks are mounted on PWB boards, which are design to interface with
automated switching and measuring equipment. Stewart Connector LLCR measuring
system consists of a Micro-Ohmmeter and a Hewlett Packard Data Acquisition Switch Unit.
Automation software is utilized to fully control the measurement sequence. Refer to
measurement configuration in Figure 4 below.
Modular Connectors
http://www.stewartconnector.com
Page 9 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
9.1
Low Level Contact Resistance: (Cont.)
FIGURE 4
9.2
Temperature Rise versus Current:
The temperature rise above ambient (25C) shall not exceed 30 C at any point on the
connector when all contacts are powered in series with 1.5 Amps DC in accordance with
EIA-364-70.
9.3
Insulation Resistance:
The insulation resistance of the unmated connectors shall be measured in accordance with
EIA-364-21. See Table 6 below:
Table 6
Insulation Resistance
Test Voltage
(VDC)
500
500
Modular Connectors
http://www.stewartconnector.com
Test Duration
Requirement
Points of Measurement
(Minutes)
(M)
1
500
Between adjacent contacts
1
500
Between contacts and shield**
** Not Applicable to Unshielded Connectors
Page 10 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
9.4
Dielectric Withstanding Voltage (DWV) Adjacent Contacts:
There shall be no arc over, insulation breakdown or excessive leakage (>1 mA) when tested in
accordance with EIA-364-20 on mated connectors. See Table 7 below:
Table 7
DWV – Adjacent Contacts
Test Voltage
1000 VACRMS or 1414 VDC
Test Duration
(Minutes)
1
Points of Measurement
Between adjacent contacts
9.5 ** Dielectric Withstanding Voltage (DWV) Contact to Shield:
There shall be no arc over, insulation breakdown or excessive leakage (>1 mA) when tested in
accordance with EIA-364-20 on mated connectors. See Table 8 below:
Table 8
DWV – Contact to Shield
Connector
Test Voltage
All Connectors
10.0
Test Duration
Points of Measurement
(Minutes)
1500 VACRMS or 2121 VDC
1
Between contacts and shield
** Not Applicable to Unshielded Connectors
Mechanical Requirements
10.1 Durability:
The durability of a connector is a conditioning sequence that is to be evaluated with reference to
a change in LLCR as specified in EIA-364-15. See Table 9 below:
Table 9
Mechanical Durability
Performance
Level
PL 1
PL 2
10.2
Rate of Travel
Cycles
(cycles/hour)
(number of times)
600
750 Total
600
2500 Total
Mated to compatible Stewart Connector
Attributable to the separable contact interface.
Gauging:
Samples must pass all gauges and forces in accordance with IEC 60603-7. Samples shall not be
capable of mating with the IEC specified No-Go gauges more than 0.070” (1.78 mm) when a
force of 2 lbs (8.9 N) is applied. Samples must be capable of mating with the IEC specified Go
gauges within the force limits in Table 10.
Table 10
Gauging – Go Gauges
Jacks
Plugs
Modular Connectors
http://www.stewartconnector.com
Max Insertion
Force
2 Lbs (8.9 N)
4.5 Lbs (20 N)
Page 11 of 14
Max Removal
Force
2 Lbs (8.9 N)
4.5 Lbs (20 N)
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
10.3
PCB Insertion Force:
A connector, not including shield solder tails or signal contacts, shall require no more than 15 lbs
(67 N) of insertion force when inserted into a minimum sized PCB hole specified on the
customer print when using pushing force rate of 0.5 inches (12.7 mm) per minute.
10.4
Mating / Unmating Force.
Mating and Unmating forces are to be measured after one cycle pre-conditioning as specified in
IEC 60603-7. See Table 11 below:
Table 11
Mating / Unmating Force
Item
Unshielded Modular
Connector
Shielded Modular
Connector
Speed
Mating Force
Unmating Force
0.4 inch/sec,
4.5 lbs,
4.5 lbs,
10.16 mm/sec
20 N
20 N
0.4 inch/sec,
6.7 lbs,
6.7 lbs,
10.16 mm/sec
30 N
30 N
All values listed are maximum values.
Modular plug tested with the latch depressed.
10.5
Discontinuity:
The mated pair shall have no discontinuities greater than 10 s when pulled against the plastic
walls in the lower (opposite latch tab) position with 4.5 lbs (20 N) minimum applied in the axial
direction. Gauge dimensions and test details are in accordance with IEC 60603-7, Annex A. See
Figure 5 below:
Insulating Block
4.5 lbs
(20 N)
Discontinuity Meter
FIGURE 5
10.6
Latch Strength.
Latch Strength will be measured in accordance with EIA-364-98. Samples shall be mounted in a
panel cutout as specified on the Customer Print as applicable. The connected pair shall
withstand an axial load of 20 pounds minimum at a rate of 0.5 inches per minute.
Modular Connectors
http://www.stewartconnector.com
Page 12 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
10.7
Mechanical Shock:
Mechanical Shock shall be measured in accordance with EIA-364-27, condition A, with
assembled connectors mounted rigidly to table and no discontinuities of >1 microsecond. See
Table 12 below:
Table 12
Mechanical Shock
Velocity
Change
(ft/s)
11.3
Wave Type
Half Sine
10.8
10.9
Number of
shocks
per direction
6
Duration
Each Face
(milliseconds)
11
Applied
Energy
(g)
50
Mutually
Perpendicular
Axis
3
Vibration (Sinusoidal):
Sinusoidal Vibration shall be measured in accordance with EIA-364-28 Test Condition I, with
assembled connectors mounted rigidly to vibrating table and no discontinuities of >1
microsecond. See Table 13 below:
Table 13
Sinusoidal Vibration
Wave Type
Amplitude
Frequency
(Hz)
Sine
.06 in. DA
10 to 55
Duration
Each Face
(hours)
2
Mutually
Perpendicular
Axis
3
Vibration (Random):
Random Vibration shall be measured in accordance with EIA-364-28 Test Condition V Letter D,
with assembled connectors mounted rigidly to vibrating table and no discontinuities of >1
microsecond. See Table 14 below:
Table 14
Random Vibration
Frequency
(Hz)
50 to 2000
Duration
Each Face
(minutes)
90
Overall
rms
(g)
11.95
Mutually
Perpendicular
Axis
3
10.10 RJ-11 Insertion:
Eight and Ten position RJ-45 jack samples shall withstand being mated 200 times with a
properly terminated six-position RJ-11 plug as specified in EIA/TIA-570.
Modular Connectors
http://www.stewartconnector.com
Page 13 of 14
Product Specification PR022-01
Date: 3-2-16
Revision: C0
Stewart Connector
10.11 Rotational Test:
Samples shall exhibit no discontinuities of >1 microsecond when subjected to the following test
sequence. See Table 15 below:
Table 15
Rotational Test
11.0
Plug
Plug Blade Height
Weight
Angle
RJ45
RJ45
0.242” / 6.15 mm
0.242” / 6.15 mm
10 lbs / 44.5 N
10 lbs / 44.5 N
45
45
Cycle
Time
6 sec
6 sec
Cycles
3 CW
3 CCW
Environmental Conditions
Note: Unless otherwise specified, all environmental testing is to be done with the connector in the mated
state.
11.1
Temperature Life:
Temperature life shall be measured in accordance with EIA-364-17, per method A. See Table 16
below:
Table 16
Temperature Life
Temperature (ºC)
85±2
11.2
Duration (hours)
500
Thermal Shock:
Thermal Shock shall be measured in accordance with EIA/TIA-568. See Table 17 below:
Table 17
Thermal Shock
Temperature
(±3 ºC)
-40 to +85
11.3
Number of
Cycles
25
Duration at Each
Extreme (Minutes)
30
Test
Condition
1
Temperature / Humidity:
Temperature / Humidity shall be measured in accordance with TIA-568 and EIA-364-31, per
method A. See Table 18 below:
Table 18
Temperature / Humidity
Relative
Humidity
(±3 %)
93
Modular Connectors
http://www.stewartconnector.com
Low
Temperature
(±2 ºC)
25
High
Temperature
(±2 ºC)
65
Cold
Sub-cycle
(±2 ºC)
-10
Page 14 of 14
Cycle
Time
(hours)
24
Number
Of
Cycles
21
Product Specification PR022-01
Date: 3-2-16
Revision: C0
工商网监
湘ICP备2023018690号
