Qualified Partner Program R&M RJ45 Connectors Felice Guarna, Training Program Manager Wetzikon, Dec. 2005

R&M RJ45 Connectors / Page 2 Dec R&M Technology: from PCB to leadframe Printed circuit board Easy lock RJ45 jack (OEM) Direct connection module R&Mfreenet R&M plug and jack First Generation Second Generation Third Generation

R&M RJ45 Connectors / Page 3 Dec R&M Technology: leadframe and beyond GET R&M RCC45 ©

R&M RJ45 Connectors / Page 4 Dec R&M RJ45 evolution, PCB module (1st generation)

R&M RJ45 Connectors / Page 5 Dec R&M RJ45 evolution, PCB module (1st generation) NEXT IBM ACS PCB module:

R&M RJ45 Connectors / Page 6 Dec R&M RJ45 evolution: DCM (2nd generation) Plug Jack Leadframe in two parts Laser soldered

R&M RJ45 Connectors / Page 7 Dec R&M RJ45 evolution: Direct Connection Module (2nd generation) NEXT ( Cat 5e performance) R&Mfreenet DCM shielded:

R&M RJ45 Connectors / Page 8 Dec R&M RJ45 evolution: Cat. 6 (3rd generation) Plug Jack a.) b.)

R&M RJ45 Connectors / Page 9 Dec R&M RJ45 evolution: Cat. 6 (3rd generation) NEXT of Pairs 3,6 - 5, MHz dB Cat. 5 TOC 40 Cat. 6 R&M Cat. 6

R&M RJ45 Connectors / Page 10 Dec Driving forces behind evolutions  Need to short signal traveling  Increase compensation as result of increased frequency  Change of plug NEXT values and method of measures  Redesign plug to achieve a semi- automated patch cord process  Improve contact geometry  Achieve interoperability and backward compatibility  Eliminate un-necessary costs by eliminating parts  Reduce workmanship  Keep all parts and processes within the company Technical Economics

R&M RJ45 Connectors / Page 11 Dec 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 / Page 12 Dec 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

R&M RJ45 Connectors / Page 13 Dec RJ45 theory, connector system RJ 45 according to IEC X Jack (fixed connector) Plug (free connector)

R&M RJ45 Connectors / Page 14 Dec RJ45 theory, pin assignment of pair 2 (3, 6) Installation cable Patch cord RJ Plug RJ Jack Connector system 1,2 3,6 5,4 7, ,2 3,6 5,4 7,8

R&M RJ45 Connectors / Page 15 Dec RJ45 theory, crosstalk in a connector system Inductive coupling Capacitive Coupling C k = C1 + C4 - C2 - C Paar 3 Paar 2 C3 C1 C2 C4 Coupling surface

R&M RJ45 Connectors / Page 16 Dec RJ45 theory, worst case pair combination 3,6 - 5,4 Pair 1 Pair

R&M RJ45 Connectors / Page 17 Dec RJ45 theory, transmission property RJ Frequenz [MHz] in dB NEXT in an uncompensated plug - jack combination: Cat 5e Limit 3,6/4,5

R&M RJ45 Connectors / Page 18 Dec RJ45 theory, how does a compensation work? Balanced transmission: + - Pair wavelength Pair 2 Compensation Crosstalk a b NEXT plug NEXT jack Compensation = 0

R&M RJ45 Connectors / Page 19 Dec RJ45 theory, function zones in a connector system Plug : Jack: Compensation:Connection technique: For example: Printed circuit board IDC block

R&M RJ45 Connectors / Page 20 Dec RJ45 theory, key factors in compensation The main characteristics of a zone are the following:  Size of compensation:X S, X B, X K phase position ( + / - )  Length of contact span:L S, L B, L K [mm]  Velocity of propagation:z LSLS LBLB LKLK XSXS XBXB XKXK

R&M RJ45 Connectors / Page 21 Dec RJ45 theory, effect of the distributed components Distributing the crosstalk over the length of the tracks and the place of origin. ===

R&M RJ45 Connectors / Page 22 Dec 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 ABC

R&M RJ45 Connectors / Page 23 Dec RJ45 theory, limits of compensation NEXT plug NEXT jack Compensated signal Compensation Amplitude variations: 20 dB / decade slope = Compensation Plug

R&M RJ45 Connectors / Page 24 Dec RJ45 theory, limits of compensation NEXT plug NEXT jack Compensated signal Compensation Phase shift due to connector length: 40 dB / decade rise Compensation

R&M RJ45 Connectors / Page 25 Dec RJ45 theory, simulation of a Cat. 5 print module Plug ConnectorJackCompensation Length [mm] = Total X-Talk [dB] = MHz NVP = 0.8 Results Frequency [MHz] =100NEXT [dB] =-42.9 Phase Shift [°] = 13.5

R&M RJ45 Connectors / Page 26 Dec RJ45 theory, example print module Effect of length Effect of amplit. Test result PCB Modul

R&M RJ45 Connectors / Page 27 Dec 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

R&M RJ45 Connectors / Page 28 Dec 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

R&M RJ45 Connectors / Page 29 Dec Interoperability between vendors Plug 1 Module 1 Cat. 6 Manufacturer 1 Plug 3Module 3 Cat. 6 Manufacturer 3 Plug 2 Module 2 Cat. 6 Manufacturer 2 Plug 2 Module 3 Cat. 6 Mix and Match

R&M RJ45 Connectors / Page 30 Dec Backwards compatibility Cat. 5 plug Cat. 5e module Cat. 6 plug Cat. 6 module Cat 5e Cat. 6 Cat. 6 plug Cat. 5e module Cat 5e Cat. 5 plug Cat. 6 module Cat. 5e

R&M RJ45 Connectors / Page 31 Dec Standardization Cat. 6 - basics Verhalten Stecker MHz Stecke NEXT Module NEXT Cat. 5 Cat. 5e Cat. 6 Plug – Module Behavior Plug

R&M RJ45 Connectors / Page 32 Dec 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

R&M RJ45 Connectors / Page 33 Dec  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

R&M RJ45 Connectors / Page 34 Dec 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

R&M RJ45 Connectors / Page 35 Dec  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 RJ45 Connectors / Page 36 Dec R&M jacks compliances  Conform to Cat. 5e requirements for connection components according to ISO/IEC and EN  Conform to EMC requirements according to EN 55022/class B (interference radiation)  UL and CSA certified  Data cables with AWG conductor diameter  Comply with reliability testing according to ISO/IEC and EN 50173

R&M RJ45 Connectors / Page 37 Dec 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

R&M RJ45 Connectors / Page 38 Dec 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

R&M RJ45 Connectors / Page 39 Dec STARsystem Cat. 6 jack, the new product

R&M RJ45 Connectors / Page 40 Dec  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

R&M RJ45 Connectors / Page 41 Dec 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

R&M RJ45 Connectors / Page 42 Dec Mechanical:  Nominal conductor diameter: solid; AWG stranded  Nominal insulation diameter: mm  Number of conductors: 1-8  Holding of conductors: IDC block (patent EP 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

R&M RJ45 Connectors / Page 43 Dec STARsystem Cat. 6, jack insertion loss

R&M RJ45 Connectors / Page 44 Dec Return Loss MHz dB 5,4 3,6 1,2 7,8 Limit STARsystem Cat. 6 jack, return loss

R&M RJ45 Connectors / Page 45 Dec STARsystem Cat. 6 jack, NEXT NEXT with a Cat. 6 plug and a Cat. 6 jack 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

R&M RJ45 Connectors / Page 46 Dec NEXT of pairs 3,6 - 5, MHz dB Cat. 5 TOC 40 Cat. 6 R&M Cat. 6 Cat. 6 and Cat. 5 jack, next comparison

R&M RJ45 Connectors / Page 47 Dec 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

R&M RJ45 Connectors / Page 48 Dec STARsystem Cat. 6 jack, Cat. 5e backward compatibility

R&M RJ45 Connectors / Page 49 Dec Cat. 6 module difference:  Test method is described in IEC 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

R&M RJ45 Connectors / Page 50 Dec 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

R&M RJ45 Connectors / Page 51 Dec EN second edition:  Chapter 8 connecting hardware requirement mechanical and electrical according to IEC ISO/IEC second Edition:  Chapter x connecting hardware requirement mechanical and electrical according to IEC and 7-5 EIA/TIA 568B Cat. 6: reference standards

R&M RJ45 Connectors / Page 52 Dec R&Mfreenet Cat 6 Jack GET 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

R&M RJ45 Connectors / Page 53 Dec Technology, application, design, material to support better performance  Process Control  More than 2000 parameters  Final test  100% of production  NEXT and RL GET R&M

R&M RJ45 Connectors / Page 54 Dec  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

R&M RJ45 Connectors / Page 55 Dec IDC contacts to connect stranded and solid wires  Improved reliability compared to piercing contacts (contact resistance)  Stranded: mm2  Solid: < 0.5 mm  Contact zone always at the same level Parallel mounting of the wire pairs on two layers  Crossing 3/6-4/5 is done in front by contacts (patent pending)  Well defined crosstalk  Superior process control STARsystem Cat. 6 plug

R&M RJ45 Connectors / Page 56 Dec 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 type Plug outer dimension R&M type

R&M RJ45 Connectors / Page 57 Dec  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