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"RJ45" crimp connector flavors

Discussion in 'Electronic Design' started by Don Y, Dec 9, 2013.

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  1. Don Y

    Don Y Guest

    Hi Peter,

    Ah ----------------------------------------------^^^^^^^^^^^^

    So, neither "COTS" nor "hand-made" (by you/your staff)
    There are noticeable differences in *jacket* O.D. -- depending on
    material, manufacturing process, etc. (some almost seem to be
    *tubing* through which the conductors are "pulled" while others
    are more conformally coated "bundles" of conductors).

    IME, usually the diameter of the conductors is enough to drive
    the jacket crimp correctly. E.g., any "slop" in the jacket gets
    squished over to the edges.

    When making a cable, I give a gentle but firm tug on the jacket
    after the crimp.

    I also don't make cables that are expected to see lots of abuse!
    Why tempt fate? :>
  2. Don Y

    Don Y Guest

    Hi Jeff,

    You're misreading my comment: THE CONTACTS ARE IDENTICAL for the
    *labeled* bags of "solid" and "stranded" connectors that I have.
    I.e., the manufacturer has apparently decided that one "universal"
    contact style is "good enough" for his production line.

    (whether that is the *optimal* choice is debatable)
    Haven't you learned that there *is* no free lunch? :>

    (I routinely "treat" salesmen, etc when I head out to lunch to warp
    the implicit bias in that "transaction": "Um, no, *I* don't 'owe you'
    any business; any information I got from you I 'paid' for :> " )
  3. Don Y

    Don Y Guest

    Hi Jasen,

    Then I guess the answer is "all of them" had to be replaced? :>
    I've only had to fabricate two such cables -- usually for serial
    consoles on 1U servers, etc. (actually, I think my APs use a similar
    cable so there must be yet another hiding somewhere!) In my case,
    I deliberately selected patch cables to butcher that would be easily
    recognizable in their "mangled" states: "Ah, this *green* cable must
    be the serial console" (leave cable connected to device with
    "useful end" dangling somewhere accessible)
    For business suppliers, cables are inexpensive. Esp in bulk.

    OTOH, the sort of person who would want to save a few bucks on
    these "expensive wires" would typically be visiting a retail store:

    $17.97 <
    $14.59 <
    $17.35 <>
    $17.99 <>
    $39.99 <>
    $20.99 <

    [sorry for wraps]

    So $20 is about what he'd expect to pay (chances are, he hasn't
    researched this as it is a purchase he infrequently makes).

    [I probably have 500 ft of patch cables "on loan" around the
    neighborhood -- silly to have friends pay for such things! "Sure,
    I can put a new connector on your cable. Yeah, they ARE pretty
    crappy. But, no, I am not going to waste time fixing your cable.
    Here's another one -- we'll just toss this one out so you aren't
    tempted to hold onto it and, someday, wonder why the network doesn't
    'see' your printer anymore... (cuz *I* won't want to have to come
    over and push the tabless connector fully into the jack!)" Did I
    mention I'm lazy in that regard? :> ]
    Operative words there are "treated properly". :>

    If everyone removed power plugs from outlets by grasping the *plug*
    instead of the *wire*, they'd last forever!

    If everyone used screwdrivers as screwdrivers and not chisels, awls
    and pry bars, they'd last forever, too!

    If people remembered that their PC was tethered to more than just
    the mains power, they'd be less likely to yank on the cable while
    still attached!

    (cable connections at the back of devices are impractical. Esp if
    there are orientation issues! Try mating a SCSI "3" cable "blind"..)

    Any time I've had to dig through a "cable box/bin" I wonder, "Why aren't
    the cables individually coiled so they don't tangle?" "Why does this
    cable have a *knot* in it?" "Why does this cable have a broken locking

    Historically, it seems folks are obsessed with holding onto defective
    and/or "undocumented" cables -- as if the wire was PLATINUM or somesuch!
    Sheesh! The time you waste trying a cable known OR SUSPECTED to be
    defective is just not worth the perceived savings!
  4. josephkk

    josephkk Guest

    Per TIA-568C.2 the (Ehternet) Category 5e network connectors are IEC
    60603-7-5. In case anyone wants to acquire a copy.

  5. Don Y

    Don Y Guest

    Hi Kevin,

    Those are destructive tests. I.e., My original goal was to be able
    to sort out "spilled" connectors based on some visual criteria as
    to whether they are intended for solid vs. stranded.

    [It appears they are for "either" and the solid vs stranded
    label is completely artificial in this instance/manufacturer]

    In the future, I'd like to make sure there is no possibility of
    confusion -- either by selecting components that are "universal"
    in application *or* are so dramatically different in appearance that
    it is really obvious when someone is using the wrong connectors!
    (If you have to resort to a microscope to figure out if the connector
    is correct, your test/inspection time goes up dramatically!)
    Ah, I didn't realize this was a variable! I thought they were all
    designed for 24AWG?
  6. josephkk

    josephkk Guest

    TIA-568 supports 22 through 28 AWG wire with 24 and 26 AWG being
    preferred. An awful lot of flexible cables are 26 AWG. Most connectors
    support only 24 AWG and 26 AWG. Some only one or t'other. Very few are
    labeled correctly.

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