qualified partner program r&m rj45 connectors felice guarna, training program manager wetzikon,...

Qualified Partner Program

R&M RJ45 Connectors

Felice Guarna, Training Program Manager

Wetzikon, Dec . 2005

R&M RJ45 Connectors / Dec. 2005

R&M Technology: from PCB to leadframe

Printed circuit boardEasy lock

RJ45 jack (OEM)

Direct connection moduleR&Mfreenet

R&M plug and jack

First Generation

Second Generation

Third Generation


R&M Technology: leadframe and beyondGET MORE @ R&M

RCC45©


R&M RJ45 evolution, PCB module (1st generation)


R&M RJ45 evolution, PCB module (1st generation)

NEXT

IBM ACS PCB module:

1 10 100100

90

80

70

60

50

40

30

20

Frequency [MHz]

[dB

]


R&M RJ45 evolution: DCM (2nd generation)

Plug

Jack

Leadframe in two partsLaser soldered


R&M RJ45 evolution: Direct Connection Module (2nd generation)

NEXT (Cat 5e performance)

R&Mfreenet DCM shielded:

1 10 100100

90

80

70

60

50

40

30

20

Frequency [MHz]

[dB

]


R&M RJ45 evolution: Cat. 6 (3rd generation)

Plug

Jack

a.)

b.)


R&M RJ45 evolution: Cat. 6 (3rd generation)

NEXT of Pairs 3,6 - 5,4

-100.00

-90.00

-80.00

-70.00

-60.00

-50.00

-40.00

-30.00

-20.00

-10.00

0.001.00 10.00 100.00 1000.00

MHz

dB

Cat. 5

TOC 40

Cat. 6

R&M Cat. 6


Driving forces behind evolutions

Need to short signal travelingIncrease compensation as result of increased frequencyChange of plug NEXT values and method of measuresRedesign plug to achieve a semi-

automated patch cord processImprove contact geometryAchieve interoperability and backward compatibility

Eliminate un-necessary costs by eliminating partsReduce workmanshipKeep all parts and processes within the company

Technical

Economics


Driving forces behind evolutions

Reduce opportunity for errors: manufacturing and terminating

Produce with automated process both jack and plug, a further step into patch cord automation

Keep performance steady and high both in production and in assembly by designing simple terminations (jack and plug without pair splitting and cross-over)

Eliminate all parts creating variance (PCB and manual soldering)

Quality


R&M RJ45 connectors

RJ45 theory

R&M positioning for jack and plug

Classic system, Cat. 5e jack

Star system, Cat. 6 jack and plug


RJ45 theory, connector system

RJ 45 according to IEC 60603-7-X

Jack

(fixed connector)

Plug

(free connector)


RJ45 theory, pin assignment of pair 2 (3, 6)

Installation cablePatch cord RJ

PlugRJ

Jack

Connector system

1,2

3,6

5,4

7,8

1

2

3

4

5

6

7

8

1,2

3,6

5,4

7,8


RJ45 theory, crosstalk in a connector system

Inductive coupling

CapacitiveCoupling Ck = C1 + C4 - C2 - C3

3 2 16

Paar 3

Paar 2

C3

C1

C2

C4

Coupling surface


RJ45 theory, worst case pair combination 3,6 - 5,4

Pair 1

Pair 2

3 4 5 6


RJ45 theory, transmission property RJ45

1 10 100100

90

80

70

60

50

40

30

20

Frequenz [MHz]

in d

B

NEXT in an uncompensated plug - jack combination:

Cat 5eLimit

3,6/4,5


RJ45 theory, how does a compensation work?

Balanced transmission:

+

-

Pair 1

-

+

1 wavelength

Pair 2

Com

pens

atio

n

Cross

talk

a

bNEXT plug

NEXT jack

Compensation

= 0


RJ45 theory, function zones in a connector system

Plug : Jack: Compensation: Connection technique:

For example:Printed circuit

board

IDCblock


RJ45 theory, key factors in compensation

The main characteristics of a zone are the following:

Size of compensation: XS, XB, XK [dB] @ phase position ( + / - )

Length of contact span: LS, LB, LK [mm]

Velocity of propagation: z

LS LB LK

XS XB XK


RJ45 theory, effect of the distributed components

Distributing the crosstalk over the length of the tracks and the place of origin.

= = =


RJ45 theory, effect of phase shift

Phase shift of the signal as a result of propagation time along the contacts.

Signal:

Result

Low frequencies

High frequencies

A B C


RJ45 theory, limits of compensation

NEXT plug

NEXT jack

Compensated signal

Compensation

Amplitude variations:

20 dB / decade slope

=

Module = -35.5 dB Kompensation

-100

-80

-60

-40

-20

0

1 10 100 1000

MHz

dB

-32 dB Stecker

-34 dB Stecker

-36 dB Stecker

-38 dB Stecker

Compensation

PlugPlugPlugPlug


RJ45 theory, limits of compensation

NEXT plug

NEXT jack

Compensated signal

Compensation

Phase shift due to connector length:

Module = -37 dB Kompensation

-100

-80

-60

-40

-20

0

1 10 100 1000

MHz

dB

70 mm Modul

45 mm Modul

30 mm Modul

15 mm Modul

40 dB / decade rise

Compensation


RJ45 theory, simulation of a Cat. 5 print module

Plug Connector Jack Compensation

Length [mm] = 20 30 10Total X-Talk [dB] = -34 -34 -28.7 @ 100 MHzNVP = 0.8 0.8 0.8

ResultsFrequency [MHz] = 100 NEXT [dB] = -42.9

Phase Shift [°] = 13.5


RJ45 theory, example print module

Simulation Printmodul

-100

-80

-60

-40

-20

0

1 10 100 1000

MHz

dB

Simulation

Einfluss Länge

Einfl. Amplitude

Messung

Effect of length

Effect of amplit.

Test result

PCB Modul


De-embedded NEXT testing of the plug (1)

1)Measuring reference plug terminated on protruding pairs

2) Cutting off protruding ends

3) Measuring reference jack with reference plug

4) Calculating influence of reference jack jack = total - plug

Reference plug

Total

Reference plug

Reference jack

Total


De-embedded NEXT testing of the plug (2)

5) Measuring test object (plug) with reference jack

6) Calculating test object (plug)plug = total - jack

Total with test object

Test object

Reference jack

Total with test object


Interoperability between vendors

Plug 1Module 1

Cat. 6

Manufacturer 1

Plug 3Module 3

Cat. 6

Manufacturer 3

Plug 2Module 2

Cat. 6

Manufacturer 2

Plug 2Module 3

Cat. 6

Mix and Match


Backwards compatibility

Cat. 5 plugCat. 5e module

Cat. 6 plugCat. 6 module

Cat 5e

Cat. 6

Cat. 6 plugCat. 5e module

Cat 5e

Cat. 5 plugCat. 6 module

Cat. 5e


Standardization Cat. 6 - basics

Verhalten Stecker - Modul@ 100 MHz

30

40

50

60

33 34 35 36 37 38 39

Stecke NEXT

Mo

du

le N

EX

T

Cat. 5

Cat. 5e

Cat. 6

Plug – Module Behavior

Plug


How do we characterize R&M jacks

Innovations: Unique shielding contact (patented) Absolutely tool-less Internal mechanically designed compensation Backward compatibility and full interoperability Special contact shape (Cat. 6 only) Front End

Innovative manufacturing process assuring: cost effectiveness less parts consistent electrical performance QUALITY

Back end

Technology

Know How


360 degree EMC protection

Earthing bridge allows free choice of ground bonding topology

Bonding by large-area (reed contact world-wide patent)

Ensures the required contact pressure for an outstanding EMC performance (high frequency also)

Ensures quick and reliable ground bonding

Ensures clean cable tension relief

Comparative tests show the superiority of shield reed contacting over conventional "clip-on" contacting

PLUS SUPERIOR PERFORMANCE

R&M jacks (EMC) features


Tool-free "Easy Lock" connection technique (IDC)

Wiring label for error-free termination (both 568 A and B type)

Conductors wired without pair crossover

SUPERIOR PERFORMANCE

Flexibility

Ri-terminatable

Used in any places (panel, outlet, MUTO, CP)

Can accept larger conductors using special easylock

Can be used in different applications: IBM GFP, keystone and special adapters

Cat. 5 and Cat. 6 modules are mechanically interchangeable

Limited dimension/easy interface allow usage in wide range of existing outlets

R&M jacks features


Easy Lock and patented screen contact makes R&M jack the quickest screened

Rj45 jack to terminate. Absolutely no tools is required and a maximum reliability

is guaranteed.

The parallel pair wiring ensures optimum twisting up to the connecting point, this

is reflected in the excellent transmission values.

Thanks to its minimum installation depth, the module can be easily installed in

the largest range of outlets or patch panels world-wide.

The R&M patented shielding contact assure fool proofs bonding and reliable

screening

THE QUICKEST AND SAFEST SHIELD TERMINATION

R&M jacks advantages


R&M jacks compliances

Conform to Cat. 5e requirements for connection components according to ISO/IEC 11801 and EN 50173

Conform to EMC requirements according to EN 55022/class B (interference radiation)

UL and CSA certified

Data cables with AWG 24-22 conductor diameter

Comply with reliability testing according to ISO/IEC 11801 and EN 50173


CLASSICsystem, Cat. 5e jack

The RJ45 jack complies with the requirements of Class De, E (125/250 MHz)

The jack complies with the requirements of Cat. 5e (125MHz)

It is the only RJ45 module to have been certified in a channel for 250 MHz and 750 MHz by an independent test laboratory (3P).

The best module worldwide for Ethernet applications in its category


STARsystem, Cat. 6 jack

Characteristics

True Cat. 6 performance (Independent certified by 3P)

Backward compatible to Cat. 5e

Traceability through integrated serial number

Integrated coding scheme

Each module tested for NEXT and RL


STARsystem Cat. 6 jack, the new product


Special spring bronze with Ni plating for enhanced performance and durability

Contacts in one piece

Gold plating in the contact area

Sn plating in the IDC area

Patent pending contact design

Flexible contacts to fit even RJ11

Contact design to minimise the distance between plug and compensation

Compensation in very small size with trimming capability

Capacitive and inductive coupling

STARsystem Cat. 6 jack, Cat. 6 the product inside


STARsystem Cat. 6 jack, Cat. 6 features

Meets the requirements for Cat. 6 connecting hardware standard according to

latest draft release (Industry agreed)

Easy and tool-less termination of all cable types (solid/stranded)

Pairs stay together up to termination point

Fits in all R&Mfreenet racks and outlets produced so far

Special colour to differentiate from Cat. 5e

Consistent electrical performance achieved through a fully automated assembly line


Mechanical:

Nominal conductor diameter: 0.5-0.65 solid; AWG 24-26 stranded

Nominal insulation diameter: 0.8-1.6 mm

Number of conductors: 1-8

Holding of conductors: IDC block (patent EP671780 B1)

Colouring scheme: type A or B possible (type A preferred)

Screen Contact: tongue (patent EP671787)

Screen: 360 degree shielding

Conductor termination cycles: 20

Plug interface cycles: > 750

STARsystem Cat. 6 jack, mechanical characteristic


Dämpfung

-0.50

-0.40

-0.30

-0.20

-0.10

0.00

1.00 10.00 100.00 1000.00

MHz

dB

5,4

3,6

1,2

7,8

Limite

STARsystem Cat. 6 , jack insertion loss


Return Loss

-100.00-90.00

-80.00-70.00

-60.00-50.00

-40.00-30.00

-20.00-10.00

0.00

1.00 10.00 100.00 1000.00

MHz

dB

5,4

3,6

1,2

7,8

Limit

STARsystem Cat. 6 jack, return loss


STARsystem Cat. 6 jack, NEXT

NEXT with a Cat. 6 plug and a Cat. 6 jack

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

110.00

120.00

1.00 10.00 100.00 1000.00

Frequency [MHz]

[dB

]

3,6 - 5,4

1,2 - 5,4

5,4 - 7,8

1,2 - 3,6

3,6 - 7,8

1,2 - 7,8

Cat. 6


NEXT of pairs 3,6 - 5,4

-100.00

-90.00

-80.00

-70.00

-60.00

-50.00

-40.00

-30.00

-20.00

-10.00

0.00

1.00 10.00 100.00 1000.00

MHz

dB

Cat. 5

TOC 40

Cat. 6

R&M Cat. 6

Cat. 6 and Cat. 5 jack, next comparison


Results of the de-embedded testing by R&M

Conclusions:

Best performer: R&M UTP and STP. The best balance between margin and standard deviation results in the best margin.

Best margin: R&M UTP combined with the second best standard deviation which guarantees the best lowest margin and therefore the first place

The R&M STP jack conquered the first place with the second best margin combined with the second best standard deviation which guarantees the best margin


STARsystem Cat. 6 jack, Cat. 5e backward compatibility

NEXT with a Cat. 5/5e plug and a Cat. 6 jack (Backward compatibility)

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00

1.00 10.00 100.00 1000.00

Frequency [MHz]

dB

3,6 - 5,4

1,2 - 5,4

5,4 - 7,8

1,2 - 3,6

3,6 - 7,8

1,2 - 7,8

Cat. 5e


Cat. 6 module difference:

Test method is described in IEC 603-7-4 and -5

The connecting hardware is measured with the plug (mated)

Specific test plug are needed

Advantages:

Interoperability between products (plug)

Full compatible to standard

Backward compatibility is guaranteed

Cat. 6 hardware: differences from Cat. 5


Interoperability:

A Cat. 6 module mated with different (vendors) Cat. 6 plugs, as defined by the

standard, must produce NEXT and FEXT values above the limits for Cat. 6

Backwards compatibility:

A Cat. 6 module mated with Cat. 5 plugs, as defined by the standard, must

produce NEXT and FEXT values above the limits for Cat. 5e

De-embedded NEXT of a plug

The de-embedded NEXT procedure is a method to determine the crosstalk

which is produced inside a plug only. The standard defines ranges of allowed

crosstalk for each pair combination and category

Cat. 6 hardware: peculiarities


EN 50173 second edition:

Chapter 8 connecting hardware requirement mechanical and electrical according to IEC 60603-7-4

ISO/IEC 11801 second Edition:

Chapter x connecting hardware requirement mechanical and electrical according to IEC 60603-7-4 and 7-5

EIA/TIA 568B

Cat. 6: reference standards


R&Mfreenet Cat 6 JackGET MORE @ R&M

Several Competitors have now Independent Labs tested Jack

Is there any difference between R&M and Competition ?

Independent Labs at the moment test only prototypes not production

Prototypes may not be real representation of current production

Prototypes to be tested by Lab can come from best production batches

Production variance depends on manufacturing process control

MANUFACTURING PROCESS CONTROL


Technology, application, design, material to support better performance

Process Control More than 2000 parameters

Final test

100% of production

NEXT and RL

GET MORE @ R&M


Thanks to special terminal based on IDC technique, the R&M plug is one of the

few available on the market allowing crimping on both solid and stranded wires

with increased contact reliability

The R&M plug is suitable for semi-automated patch cord production

The R&M plug is only terminated and tested in factory

Positioning plug: flexibility


IDC contacts to connect stranded and

solid wires Improved reliability compared to

piercing contacts (contact resistance)

Stranded: 0.09-0.22 mm2 Solid: < 0.5 mm Contact zone always at the same

levelParallel mounting of the wire pairs ontwo layers

Crossing 3/6-4/5 is done in front by contacts (patent pending)

Well defined crosstalk Superior process control

STARsystem Cat. 6 plug


STARsystem Cat. 6 plug

Housing of tin plated brass

Standard outer dimensions

New strain relieve

Cables are fixed 360 degree

Pairs stay at the same place

Better performance

For screened cables additionally

Screen contact 360 degree

Lifetime screen contact

Common typePlug outer dimension

R&M type


The first connecting hardware which meets the relevant Cat. 6 hardware requirement

Independent lab certified: 3P, Delta, GHMT

First Cat. 6 module without PCB

As easy as Cat. 5 to terminate

Same connecting hardware at distributor and outlet side

Next and RL tested 100% in production

STARsystem Cat. 6 jack an plug, summary

qualified partner program r&m rj45 connectors felice guarna, training program manager wetzikon,...

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