Product 108-131013

Specification 23 DEC 15 Rev. A

Modular Plugs, Unshielded and Shielded

1. SCOPE

1.1. Content

This specification covers performance, tests and quality requirements for Shielded and Unshielded
Modular Plugs used to provide a universal connection interface between premise wiring of an office and
the user’s network of communications equipment (for data and voice networking systems). These
assemblies are designed for installation onto various cables. Plugs incorporate IPC terminal for
terminating twisted pair communications cable. See customer drawings for cable conductor diameter,
insulation diameter and cable diameter compatibility
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.

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. CommScope® Documents
• 501-131013: Qualification Test Report (Modular Plugs) Revision A
• 408-8734 Terminating Modules 791804-[ ] for Use with Modular Plug Dual Terminators
• 408-8738: PRO-CRIMPER* III Hand Crimping Tool Assembly 790163-[ ]
• 408-9930: PRO-CRIMPER* III Hand Crimping Tool Frame Assembly 354940-[ ]
• 409-10010 Modular Plug Dual Terminator 1320840-[ ]

2.2. Industry Documents

• ISO/IEC 11801: Edition 2.2 : Generic Cabling for Customer Premises
• ISO/IEC 60603-7 Edition 3.1: Detail Specification for 8-way, Unshielded, Free and Fixed Connectors
• ISO/IEC 60603-7-1 Edition 3.0: Detail Specification for 8-way, Shielded, Free and Fixed Connectors
• ANSI/TIA-568-C.2: Balanced Twisted-Pair Telecommunications Cabling and Components Standards
• IEC 61935-2 Edition 3.0: Specification for the Testing of Balanced and Coaxial Information Technology
Cabling – Part 2: Cords as Specified in ISO/IEC 11801 and Related Standards
• IEC 60352-6 Edition 1.0: Insulation Piercing Connections- General Requirements, Test Methods and
Practical Guidance
• IEC 60512: Basic Testing Procedures and Measuring Methods for Electromechanical Components for
Electronic Equipment (as indicated in Figure 1)
• IEC 60068: Basic Environmental Testing Procedures (as indicated in Figure 1)

© 2015 CommScope, Inc. 1 of 9

All rights reserved
 108-131013

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. Wire Range
• See specific customer drawings for appropriate cable dimensions compatibility
3.4. Ratings
• Voltage: 150 volts AC maximum
• Current: Signal application only, 0.75 ampere maximum
• Temperature: -10 °C to +60 °C (per ISO/IEC 11801, Section 10.1.4)
Increased temperatures will affect the current carrying capacity of the electrical system.
Consult the Environmental Testing section of this specification and the De-rating Curve, per
IEC 60603-7, Figure 10 to determine the appropriate application of product.
3.5. Tooling
Connectors shall be terminated using Modular Plug tooling shown in the application specification,
customer drawings, and instruction sheets appropriate for each part number.
3.6. Performance and Test Description
Product is designed to meet the electrical, mechanical and environmental performance requirements
specified in Figure 1. Unless otherwise specified, all tests shall be performed at ambient environmental
conditions.

Examination
Test Description Requirement Procedure
Initial examination of product ISO/IEC 11801, Annex C IEC 60512-1-1 and -2
There shall be no defects that would Visual and dimensional per quality inspection
impair normal operation. Dimensions plan with Certificate of Conformance (C of C)
shall comply with those specified on
product drawing.

Verify contact termination heights IEC 60603-7 unshielded or 60603-7-1 for

shielded connectors

Verify plating thicknesses Dimensional per quality inspection plan with

Certificate of Conformance (C of C) or
laboratory verification
Visual examination of product ISO/IEC 11801, Annex C IEC 60512-1-1
There shall be no defect that would Visual inspection.
impair normal operation.
Length, uncoiled patch cord Length to be within print tolerance Measure physical length of patch cord as
shown on customer drawing

Rev. A 2 of 9
 108-131013

ELECTRICAL
Test Description Requirement Procedure
Contact resistance, IEC 60352-6, Section 5, Table 2 IEC 60512-2-1
IPC/wire interface Initial: Derived by measuring the total voltage drop
IPC/wire: 10 mΩ max. between the plugs IPC contact and
terminated wire, then subtracting the
Change from initial after conditioning: average bulk resistance of these
IPC/plated wire: 10 mΩ max. components. Test voltage shall not exceed
IPC/un-plated wire: 15 mΩ max. 20 mV d.c. or peak voltage a.c. and test
current shall not exceed 100 mA, a.c. or d.c.
(See Figure 4)
Input to output DC resistance IEC 60603-7, Section 6.4.5. IEC 60512-2-1.
TIA-568-C.2, Section 6.8.1. Derived by measuring the total voltage drop
Signal conductors (RAD): 200 mΩ of terminated plugs mated to terminated
max. jacks.
(See Figure 3)
IEC 60603-7-1, Section 6.4.5
Shield (RAD): 100 mΩ max.
Input to output DC resistance IEC 60603-7, Section 6.4.6. IEC 60512-2-1.
unbalance Difference between all signal Derived by calculating the maximum
conductors (RAD): 50 mΩ max. difference between input to output DC
resistance measurements.
(See Figure 3)
Insulation Resistance IEC 60603-7, Section 6.4.7 IEC 60512-3-1, Method A.
500 megaΩ minimum 100 volts DC, 1 minute hold.
Voltage proof IEC 60603-7, Section 6.4.2 IEC 60512-4-1, Method A.
One minute hold with no breakdown 1000 volts DC or AC peak. Terminated jack
or flashover. with mated plug. One contact to all other
contacts connected together. All contacts
bundled to shield, 1500 volts DC or AC peak.
Current temperature de-rating IEC 60603-7, Section 6.4.3 IEC 60512-5-2, test 5b
Shall comply with de-rating curve. Contacts connected in series.
MECHANICAL
Test Description Requirement Procedure
Locking device mechanical 60603-7, Visual examination, locking 60603-7 Annex B
operations device must function in jack and 1,500 operation cycles. Locking device shall
show no indication of stress cracking. be depressed until it contacts the body of the
See Note (a) plug. Speed shall not exceed 20 cycles per
minute.
Plug insertion & withdrawal IEC 60603-7, Section 6.6.3 IEC 60512-13-2.
force Unshielded connectors: 20 N max. Measure force required to mate/unmate plug
& jack with latch depressed at a constant
IEC 60603-7-1, Section 7.7.2.3 speed with a maximum rate of 50 mm per
Shielded Connectors: 30 N max. minute.
Plug retention in jack IEC 60603-7, Section 6.6.2. IEC 60512-15-6.
(effectiveness of connector No discontinuities greater than 10 µs. Apply an axial load of 50 N to plug mated to
coupling device) Shall remain mated and show no jack with latch engaged and hold for 60±5
evidence of physical damage. seconds. Load shall be applied at a
See Note (a) maximum rate of 44.5 N per second.
Mechanical operations IEC 60603-7, Section 6.6.1. IEC 60512-9-1.
durability See Note (a) Mate and unmate plug to jack interface with
locking device inoperative for 375 cycles at a
maximum rate of 10mm per second.

Rev. A 3 of 9
 108-131013

Bending of the wire/cable IEC 60352-6, Section 5.2.2.2 IEC 60352-6, Section 5.2.2.2
No discontinuities greater than 10 µs.
Apply a 22 N axial load to the free end of
Termination shall not be damaged cable terminated to a plug Bend cable α = 30
and conductors shall not be broken. degrees in both directions from vertical
See Note (a) position for 5 cycles each direction (10
cycles total). Monitor contact disturbance per
IEC 60512-2-5.
Vibration, IEC 60603-7, Section 7.7.2.5. IEC 60512-6-4.
Plug/Jack interface No discontinuities greater than 10 µs. Subject mated plug & jack to:
Shall remain mated and show no Frequency: 10 to 500 Hz.
evidence of physical damage. Displacement Amplitude: 0.35 mm
See Note (a) Acceleration: 5g (50 m/s2)
10 sweep cycles per axis of 3 mutually
perpendicular planes.
Sweep rate: 1 octave per minute.
Refer to IEC 60603-7, Section 7.3, for
arrangement of vibration test. Monitor
contact disturbance per IEC 60512-2-5.
Vibration, IEC 60352-6-7, Section 5.2.2.3 IEC 60512-6-4.
IPC/wire interface No discontinuities greater than 10 µs. Subject terminated plug to:
Shall show no evidence of physical Frequency: 10 to 55 Hz.
damage. See Note (a) Displacement Amplitude: 0.35 mm
10 sweep cycles per axis of 3 mutually
perpendicular planes.
Full Duration: 2.25 hours. Test specimen
shall be firmly held on a vibration table.
Monitor contact disturbance per IEC 60512-
2-5.
Tensile, patch cord IEC 61935-2, Section 6.2 Tensile force: 22 N applied along the
1 mm maximum outer cable sheath common axis of the cable & plug.
movement relative to plug boot. Duration: 1 minute
See Note (a) Electrical testing not required during tensile.
Flexural, patch cord IEC 61935-2, Section 6.3 Test shall be performed using fixture setup
Shall show no evidence of physical similar to that shown in Figure 5 of this spec.
damage. See Note (a) Axial force applied on cable: 2 N
Total cycles divided between two
perpendicular axis:
Stranded conductor: 250 (0°/+90°/-0°/-90°/0°)
Solid conductor: 50 (0°/+90°/-0°/-90°/0°)
Rate of flex: 20 complete cycles per minute.
Electrical testing not required during flexure.
Torsional, patch cord Shall show no evidence of physical Test shall be performed using fixture setup
damage. See Note (a) similar to that shown in Figure 6 of this spec.
Twist length: 330 mm
Axial force applied to cable: 10 N
Total cycles: 100 (0°/+180°/0°/-180°/0°)
Rate of torsion: 20 complete cycles per
minute.
ENVIRONMENTAL
Test Description Requirement Procedure
Rapid change of temperature, IEC 60603-7, Section 7.7.2.3. IEC 60068-2-14, Test Na or Nb
Plug/Jack interface See Note (a) Subject mated connectors to 25 cycles
between -40°C & 70°C with 30 minute dwells
at temperature extremes. 2 hour recovery
time.
Rapid change of temperature, IEC 60352-6, Section 5.2.4.1 IEC 60068-2-14, Test Na or Nb
IPC/wire interface See Note (a) Subject terminated plugs to 5 cycles
between -40°C & 70°C with 30 minute dwell
at temp. extremes. 2 hour recovery time.

Rev. A 4 of 9
 108-131013

Cyclic damp heat IEC 60603-7, Section 7.7.2.3. IEC 60068-2-38.

See Note (a) Subject connectors to 21 cycles (21 days)
between 25°C & 65°C at 93% RH with 5 sub-
cycle shocks at -10°C in the 1 st 9 cycles. Half
specimens mated, other half unmated.
Climatic sequence 60352-6 Section 5.2.4.2 IEC 60068-2-61, Method 1
See Note (a) Subject terminated plugs to dry heat +70°C &
cold -40°C for 1 cycle.
Electrical load & temperature IEC 60603-7, Section 7.7.2.6 IEC 60068-2-2, Tests Bd & Be
See Note (a) Temperature: 70°C, RH: uncontrolled
Test Time: 500 hours & 2 hours recovery
Test Currents:
Signal contacts: 0.8A d.c. per contact
Half the specimens energized [test Be], the
remaining half not energized [test Bd].
Flowing mixed gas corrosion, IEC 60603-7, Section 7.7.2.4 IEC 60512-11-7, Method 1.
Plug/Jack interface See Note (a) H2S: 100 ± 20 (10-9 vol/vol),
SO2: 500 ± 100 (10-9 vol/vol),
Temp.: 25 ± 1°C, RH: 75 ± 3%,
Test time: 4 days,
Half specimens mated, other half unmated.
Flowing mixed gas corrosion, IEC 60352-6, Section 5.2.4.3 IEC 60512-11-7, Method 1.
IPC/wire interface See Note (a) H2S: 100 ± 20 (10-9 vol/vol),
SO2: 500 ± 100 (10-9 vol/vol),
Temp.: 25 ± 1°C, RH: 75 ± 3%,
Test time: 10 days
TRANSMISSION (Stranded Conductors Only)
Patch Cord Component
Test Description Requirement Procedure
Wire Map Wiring pattern as specified in test IEC 61935-2 Section 5.2, as specified
request. If not otherwise noted, test in the coiled state.
Return Loss, Coiled TIA-568-C.2, Section 6.2.6 IEC 61935-1, Section 5.6
TIA-568-C.2, Annex C.5.2.3,
Test in coiled state
Pair to Pair Near End Crosstalk ISO 11801, Section 6.4.4.1, IEC 61935-1, Section 5.7
(NEXT) loss, Coiled TIA-568-C.2, Section 6.2.8, TIA-568-C.2, Annex C.5.2.1,
Test in coiled state
Return Loss, Uncoiled TIA-568-C.2, Section 6.2.6 IEC 61935-1, Section 5.6
TIA-568-C.2, Annex C.5.2.3,
Test in uncoiled state.
Pair to Pair Near End Crosstalk ISO 11801, Section 6.4.4.1, IEC 61935-1, Section 5.7
(NEXT) loss, Uncoiled TIA-568-C.2, Section 6.2.8, TIA-568-C.2, Annex C.5.2.1,
Test in uncoiled state.

Figure 1
NOT

(a) Shall meet visual requirements, show no physical damage, and meet requirements of additional tests
specified in the Product Qualification and Requalification Test Sequence shown in Figure 2.

Rev. A 5 of 9
 108-131013

3.7. Product Qualification and Requalification Test Sequence

Test Sequence
IPC / Wire Patch
Test or Examination Plug / Jack
Interface Cord
A1 A2 A3 B1 B2 B3 B4 B5 C1
Initial examination of product 1 1 1 1 1 1 1 1 1

Visual examination of product 5 7 5 12,17 13 8 8 3 13

Length, uncoiled patch cord 5

Contact resistance, IPC/wire interface 2,4 2,6 2,4

Input to output resistance

2,7,10,14 4,6,8,10 2,6 2,9
Input to output resistance unbalance

Insulation resistance 3,9 2,11 3,7 3,6

Voltage proof 4,11 3,12 4 4,7

Current carrying capacity 2

Plug insertion & withdrawal force 5,15

Plug retention in jack 6,16

Cable bending 3

Mechanical operation durability 5,9

Vibration, plug/jack 5

Vibration, IPC/wire 3

Tensile, patch cord 8

Flexural, patch cord 9

Torsional, patch cord 10

Rapid change of temp, plug/jack 8

Rapid change of temp, IPC/wire 4

Cyclic damp heat 13

Climatic Sequence 5

Electrical load and temperature 5

Flowing mixed gas corrosion,
7
plug/jack
Flowing mixed gas corrosion, IPC/wire 3

Wire Map, patch cord coiled 2

Return Loss, patch cord coiled 3

Next loss, patch cord coiled 4

Return Loss, patch cord uncoiled 6, 11

Next loss, patch cord uncoiled 7, 12

Figure 2

Rev. A 6 of 9
 108-131013

4. QUALITY ASSURANCE PROVISIONS

4.1. Qualification Testing

A. Specimen Selection
Modular Plugs: Specimens shall be selected at random from current production and prepared in
accordance with applicable Instruction Sheets.

Cable: Engineering discretion, customer drawings and product specifications shall be used to
choose cables to qualify/requalify new products and design changes. Cables may be chosen with
minimum and maximum conductor sizes, insulations sizes and jacket sizes commonly available in
the industry.
B. Test Sequence

Product qualification shall be verified by testing specimens per test sequence defined in Figure 2.

4.2. Requalification Testing

If changes significantly affecting form, fit or function are made to the product or 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. If product
failure occurs, corrective action shall be taken and specimens resubmitted for qualification. Testing to
confirm corrective action is required before resubmittal.
4.4. Quality Conformance Inspection
The applicable quality inspection plan shall specify the sampling acceptable quality level to be used.
Dimensional and functional requirements shall be in accordance with the application product drawing
and this specification.

5. FIGURES RELATED TO TEST PROCEDURES

Resistance of Connector Assembly

Figure 3

Rev. A 7 of 9
 108-131013

R
 Contact Resistance
R
Contact (Bulk)


R
Wire (Bulk)

Sense HI Source HI

IPC Contact Resistance = R
= RPlug (Bulk) - R - R

Contact Resistance of RJ Style Plug

Rev. A 8 of 9
 108-131013

Figure 4

Flexural Test Torsional Test

Figure 5 Figure 6

6. REVISION SUMMARY

• Rev. A – Initial release.

Rev. A 9 of 9