Revised Jan-23-2013 Sealed Industrial Ethernet Circular IP67 Cat. 5e RJ45 Connector System Assembly Instructions CONEC Industrial Ethernet Circular Sealed RJ45 Connector System consists of a RJ45 Plug Kit, a Receptacle Kit and a Protective Cover Assembly. 1. The RJ45 Plug Kit 1.1 Introduction The Cat. 5e RJ45 plug kit consists of a shielded 8 position Cat. 5e RJ45 Plug, a Load Bar and a Plug Housing Assembly (Bayonet). The Cat. 6A RJ45 plug kit consists of a shielded 8 position Cat. 6A RJ45 Plug, a Load Bar, a Wire Fixer and a Plug Housing Assembly (Bayonet). There are 4 different versions available for the Plug Housing Assembly, plastic, metallized plastic, Metal and Zinc Die-cast. See Figure 1-1 and Figure 1-2 for details. Figure 1-1: Cat. 5e RJ45 Plug Kit Figure 1-2: Cat. 6A RJ45 Plug Kit 2 Cable Strain Relief Kit 2.1 Introduction The RJ45 cable strain relief kit consists of a shielded 8 position Cat. 5e RJ45 Plug, a Load Bar and a Plug Housing Assembly (Thread). The Cat. 6A RJ45 plug kit consists of a shielded 8 position Cat. 6A RJ45 Plug, a Load Bar, a Wire Fixer and a Plug Housing Assembly (Thread). Page 1 of 15 There are 2 different versions available for the Plug Housing Assembly, plastic and metallized plastic. See Figure 2-1 and Figure 2-2 for details. Figure 2-1: Cat. 5e RJ45 Cable Strain Relief Kit Figure 2-2: Cat. 6A RJ45 Cable Strain Relief Kit The RJ45 plug accepts both stranded and solid cables. It can be IDC terminated with the termination tool. The load bar aligns the wires for insuring easy and proper assembly. The Wire Fixer separate the wire pairs helping to archive Cat. 6A performance. 3 Ethernet Cable The following specified category 5e 100Ω shielded and unshielded twisted pair cables (STP and UTP) and Cat. 6A Screened shielded twisted pair (SSTP) cables are suitable for use with the RJ45 Plug Kit. Plastic version of the cable fitting accepts cables with an outer diameter range of 4mm to 8mm while 4.5mm to 8mm for the metallized plastic version. A. Stranded Wire of cat. 5e Cable Cable type: 8 positions Conductor size: 24 AWG Conductor type: 7 strand copper Contact insulator diameter: 0.99mm maximum RJ45 plug accepts cable outer diameter range: 4.83mm ~ 6.73mm B. Solid Wire of Cat. 5e Cable Cable type: 8 positions Conductor size: 24 AWG Conductor type: copper Page 2 of 15 Contact insulator diameter: 0.99mm maximum C. Stranded Wire of cat. 6A Cable Cable type: 8 positions Conductor size: 26 AWG Conductor type: 7 strand copper Contact insulator diameter: 0.99mm maximum RJ45 plug accepts cable outer diameter range: 4.83mm ~ 6.73mm D. Solid Wire of Cat. 6A Cable Cable type: 8 positions Conductor size: 26 AWG Conductor type: copper Contact insulator diameter: 0.99mm maximum RJ45 plug accepts Loose, Pliable cable outer diameter range: 4.83mm ~ 6.73mm RJ45 plug accepts Hard, Rigid cable outer diameter range: 4.83mm ~ 5.08mm 3.1 Cable Preparation 3.1.1 Cable jacket should be stripped with the proper length as shown in figure 3-1 and then inserted through the cable fitting and the plug housing assembly. Figure 3-1: Cable Preparation Step 1 3.1.2 Conductor pair should be untwisted and aligned side-by-side according to EIA/TIA T568A or T568B (defined in Figure 3-2 and Table 1-1) and the conductor tips should be trimmed as shown in Figure 3-3 and Figure 3-7. Please note that insulation of individual conductors must not be removed. Page 3 of 15 Figure 3-2: EIA/TIA T568A & T568B Plug Positions T568A T568B Table 1-1: TIA/EIA T568A & T568B Conductor Pairs and Wire Colors Conductor Pair Pair 1 Pair 2 Pair 3 Pair 4 Conductor Pair Definitions Wire Color Code (Abbreviation) T568A T568B Option 1 Option 2 4 4 Blue (BL) Red (R) 5 5 White-Blue(W-BL) Green (G) 3 1 White-Orange (W-O) Black (BK) 6 2 Orange (O) Yellow (Y) 1 3 White-Green (W-G) Blue (BL) 2 6 Green (G) Orange (O) 7 7 White-Brown (W-BR) Brown (BR) 8 8 Brown (BR) Slate (S) Figure 3-3: Cable Preparation Step 2 Page 4 of 15 3.2 Termination 3.2.1 Cat. 5e RJ45 Plug Termination 3.2.1.1 After inserting the wires into the appropriate positions of the load bar, slide the cable to a point where the cable jacket hits against the notch of the load bar. Trim the remaining wire ends to approximately 5mm length of the wire tips as shown in Detail A of Figure 3-4. Retract the cable, leaving about 1mm length of the wire tips as shown in Detail B of Figure 3-4. Figure 3-4: Insert Conductors into the Load bar 3.2.1.2 Insert the wired load bar into the RJ45 plug all the way until the wire tips are seated against the inside wall of the plug housing (Figure 3-5). For shielded version adjust the drain wires of the cable to touch the metal shell of the RJ45 Plug (Figure 3-6). Cut out extra drain wire after termination. Figure 3-5: Insert the wired load bar into plug Page 5 of 15 Figure 3-6: Place the drain wire of the cable to touch the metal shell of the shielded plug 3.2.2 Cat. 6A RJ45 Plug Termination 3.2.2.1 Place the wire pair into the cavity of the Wire Fixer where Pair 1 (Blue/White-Blue) in bottom cavity, Pair 2 (White-Orange/Orange) in left side cavity, Pair 3 (WhiteGreen/Green) in top cavity and Pair 4 (White-Brown/Brown) in the right side cavity. Push the wire fixer to against the braid shield of the cable. Trim the remaining wire ends to approximately 5mm length of the wire tips as shown in Figure 3-7. Figure 3-7: Place the wire pair into the cavity of the wire fixer Page 6 of 15 3.2.2.2 Insert the wire into the load bar as show in Figure 3-8. Figure 3-8: Insert the wire into load bar 3.2.2.3 Insert the wired load bar and wire fixer into the RJ45 plug all the way until the loard bar hit the inside wall of the plug housing (Figure 3-9). Adjust the braid shield of the cable to touch the metal shell of the RJ45 Plug (Figure 3-10). Cut out extra braid shield after termination. Figure 3-9: Insert the wired load bar and wire fixer into plug Figure 3-10: Place the drain wire of the cable to touch the metal shell of the shielded plug Page 7 of 15 3.2.3 Terminate the cable and the RJ45 Plug with CONEC 8P8C modular plug termination tool (Figure 3-11). Depress the locking tab of the plug, insert the plug and cable into the termination head up to the end of the inside plug housing wall and terminate. Depress the locking tab of the plug and pull the plug from the tool after termination. Figure 3-11: 8P8C Modular Plug Termination Tool (P/N: 360X30029X) Termination Head 3.2.4 Test the pin configuration of the assembled cable for accuracy using the NETWORK Multi-Modular Cable Tester (Figure 3-12). Figure 3-12: Network Multi-Modular Cable Tester (P/N: 360X30039X) Top View Left View Front View Detachable Figure 3-13: Shielded Cat. 5e RJ45 Plug (P/N: 391J00039X) Page 8 of 15 Bottom View Figure 3-14: Shielded Cat. 6A RJ45 Plug (P/N: 391J00049X) The Modular Plug Termination Tool (Figure 3-11), the NETWORK Multi-Modular Cable Tester (Figure 3-12) and the RJ45 Plug (Figure 3-13 and 3-14) can be ordered separately. 4 Assembly of the RJ45 Plug Housing Depress the locking tab of RJ45 Plug and align it with the wide slot of the plug housing shown in Detail A of Figure 4-1. Gently pull the cable until the plug is fully seated. Hold the plug in position and rotate the cable fitting until tightened to a torque of 2.27 Nm (20 lb-in). See Detail B of Figure 4-1. Figure 4-1: Assembly of the RJ45 Plug Housing Detail A Detail B Page 9 of 15 5. The Receptacle Assembly Kit 5.1 The Cat. 5e RJ45 Inline Coupler Receptacle Assembly Kit This Receptacle Assembly kit consists of a RJ45 Inline Coupler Receptacle Assembly, a Panel Gasket and a Panel Nut. There are plastic and metallized plastic versions available for the Receptacle Housing. See Figure 5-1 for details. Figure 5-1: Cat. 5e RJ45 Inline Coupler Receptacle Assembly Kit Groove for tether Flat Bayonet Channel x3 Cat. 5e RJ45 Inline Coupler Panel Gasket Panel Nut Flange Receptacle Housing RJ45 Inline Coupler Receptacle Assembly 5.2 The Cat. 5e RJ45 IDC Jack Receptacle Assembly Kit This Receptacle Assembly kit consists of a RJ45 IDC Jack Receptacle Assembly, a Panel Gasket and a Panel Nut. There are plastic and metallized plastic versions available for the Receptacle Housing. See Figure 5-2 for details. Figure 5-2: Cat. 5e RJ45 IDC Jack Receptacle Assembly Kit Flat Bayonet Channel x3 Groove for tether Shielded Cat.5e RJ45 IDC Jack accepts both Solid and Stranded AWG 24 to 26 Wires Panel Gasket Panel Nut IDC Terminator Flange Receptacle Housing Page 10 of 15 RJ45 IDC Jack Receptacle Assembly Use the 110 type punch-down tool (Figure: 5-3) to terminate the wires to the IDC terminator of the IDC Jack. Figure 5-3: 110 Type Punch-Down Tool (P/N: 360X30049X) 5.3 The Cat. 5e RJ45 PCB Jack Receptacle Assembly Kit This Receptacle Assembly kit consists of a RJ45 IDC Jack Receptacle Assembly, a Panel Gasket and a Panel Nut. This PCB version is designed to solder the wires direct onto the PCB of the Jack. There are plastic and metallized plastic versions available for the Receptacle Housing. See Figure 5-4 for details. Figure 5-4: Cat. 5e RJ45 PCB Jack Receptacle Assembly Kit Bayonet Channel x3 Groove for tether Flat Shielded Cat.5e RJ45 PCB Jack accepts both Solid and Stranded AWG 24 to 26 Wires Panel Gasket Panel Nut Flange Receptacle Housing RJ45 PCB Jack Receptacle Assembly 6 Protective Cover Assembly 6.1 Introduction The Protective Cover Assembly consists of a Cover Coupling Ring, a Cover Gasket and a Tether. There are plastic and metallized plastic versions available for the Cover Coupling Ring housing. See Figure 6-1 for details. Page 11 of 15 Figure 6-1: Protective Cover Assembly Protective Cover Loop of the Tether Key Protrusion (3 Keys) Cover Gasket Tether 7. The Receptacle + Protective Cover Assembly Kit 7.1 Introduction This kit combines the different version of the Receptacle Assembly and the different version of the Protective Cover Assembly. See Figure 7-1 for details. Figure 7-1: Receptacle + Protective Cover Assembly Kit Cat.5e RJ45 Shielded or Unshielded Coupler, IDC Jack or PCB Jack Panel Gasket Panel Nut + Protective Cover Assembly Receptacle Assembly Page 12 of 15 8 Panel Cutout 8.1 Introduction A panel thickness of up to 3.20 mm may be used. The recommended panel cutout dimension for plastic, metallized plastic and metal versions are shown in Figure 8-1 while Figure 8-2 is the recommended panel cutout dimension for zinc die-cast version and Figure 8-3 is the recommended panel cutout dimension for flange mount zinc die-cast version. Figure 8-1: Recommended Panel Cutout for Plastic, Metallized Plastic and Metal Version Flat Edge Figure 8-2: Recommended Panel Cutout for Zinc Die-Cast Version Figure 8-3: Recommended Panel Cutout for Flange Mount Zinc Die-Cast Version Page 13 of 15 8.2 Panel Mounting The receptacle is designed for front or rear panel mounting as shown in Detail B and Detail A of Figure 8-2. The panel nut should be tightened to a torque of 2.27 Nm (20 lb-in). The Protective Cover must be installed onto the Receptacle Assembly and cover the receptacle immediately for insuring the IP67 sealing performance once the Plug Assembly is removed from the receptacle. Figure 8-2: The Receptacle Panel Mounting Protective Cover Assembly Panel Nut tight in 2.27 Nm (20 lb-in) Flange Protective Cover Assembly Panel Gasket Receptacle Assembly Flange Panel Nut tight in 2.27 Nm (20 lb-in) Receptacle Assembly Panel Gasket Back of Panel Front of Panel Detail A: Rear Panel Mount Detail B: Front Panel Mount 9 Connector Engagements 9.1 RJ45 Jack and Plug Engagement (Bayonet) Gently insert the assembled plug (Bayonet) into the Jack adaptor of the RJ45 receptacle, align the 3 keys of the bayonet coupling ring with 3 bayonet channels of the receptacle and rotate the bayonet coupling ring until the 3 keys “click” into the bayonet channels. See Detail A of Figure 9-1. 9.2 RJ45 Jack and Plug Engagement (Cable Strain Relief) Gently insert the assembled plug (Thread) into the Jack adaptor of the RJ45 receptacle then fully thread the M28 coupling ring. See Detail B of the Figure 9-1. 9.3 Protective Cover Engagement The protective cover must be installed onto the Receptacle Assembly and engaged with the receptacle immediately for insuring IP67 sealing performance whenever the Plug Assembly (Bayonet) is removed from the Receptacle Assembly. The tether of the protective cover should be attached to the Receptacle Assembly if it is to be used. Place the loop of the tether in the groove (located between the end of the bayonet channels and the hex nut) of the Receptacle Assembly. See Detail C of Figure 9-1. Page 14 of 15 Figure 9-1: Connector Engagement Bayonet coupling ring M28 Thread coupling ring Press & Rotate Plug Assembly (Thread) Receptacle Assembly Plug Assembly (Bayonet) Loop of the Tether attach to the Groove of the Receptacle Assembly Receptacle Assembly Fully thread the M28 Coupling ring Detail B: RJ45 Jack and Plug Engagement (Cable Strain Relief) Panel Press & Rotate Protective Cover Assembly Protective Cover Assembly Detail A: RJ45 Jack and Plug Engagement Page 15 of 15 Receptacle Assembly Detail C: Cover Engagement