Protecting Modular Plugs from Breakage
Ron Bean (KJ5XX)
on
June 16, 2008
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If you have one of the newer rigs from Icom, Kenwood and others, you are probably familiar with the trend toward using modular (RJ45 type) jacks in place of the older, and sturdier 4, 6, and 8 pin connectors. Why are the rig manufacturers going away from something that not only worked but has been the standard for decades? Simple - cost.
Of course modular connectors are nothing new, they too have been around for decades. The difference is that the old style pin connector could be disconnected and re-connected many times, with no deterioration in performance. RJ45 type modular connectors were designed to be connected ONCE and then left where they were connected. As a result they are commonly used in telecommunications cabling and Ethernet cables.
The problem with applying this type of connector to ham applications is that many times a mic may be connected, disconnected and re-connected as a rig is used for portable or other operation. Over time the clip weakens and eventually breaks.
If you've never tried putting on a modular jack, it can be very tricky! One false move with a bad crimp and you can cost you big $$ in expensive rig repairs. The other issue is that even though the modular jacks in use by Icom and others "look" like RJ45 jacks - they usually are slightly different. As a result, don't even try to use the kind of crimping tool they sell at Radio Shack - it just doesn't work. These jacks generally require specialized (and expensive) crimping tools and associated dies.
There is a solution that I've found that at least can help protect your modular jack and hopefully extend the life of it. These little modular jack protectors or boots simply snap over the your existing modular jack and protect it both while in use and when not.
There are really two types of these boots - "pre-assembly" which are commonly referred to as modular jack protectors or RJ45 "boots". The one you want are those designed for putting onto an RJ45 connector AFTER it is connected to the mic cable, commonly called "post-assembly RJ45 boots" (although they may go by other names as well).
Probably the easiest way to search for these on the web is to use the words "post assembly RJ45 boot" or "RJ45 snap-on boot."
Here are a few places I've found that sell these (you can easily see the split construction in some of these):
http://www.lindy.com/us/productfolder/06/60386/index.php
amazon.com
Why the rig manufacturers don't put these on their mic cables is beyond me, but at least there is a cheap alternative. Sometimes it takes the ham community to make "improvements" to vendor products before they actual catch on. >(:?D
73,
Ron - KJ5XX
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Protecting Modular Plugs from Breakage
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by VK4NEF on June 16, 2008
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Thanks for the tip Ron, I tried your first link and found that the grey colour is discontinued, good link is: http://www.lindy-usa.com/post-assembly-rj-45-male-strain-relief-boot-black-10-per-pack/60385.html
I use two Kenwood TS480s here and with your post I noted that the Heil adapter AD-1KM has the strain relief boot fitted, will purchase some for the remote head to radio lead.
Regards
Eric VK4nef
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RE: Protecting Modular Plugs from Breakage
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by K0BG on June 16, 2008
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When modular plugs fail, it is usually caused by catching the retaining clip on some other object, not because you've removed it several times. The cover will certain prevent that. This said, depending on the brand, the cover may protrude far enough that proper insertion isn't possible. A little trimming with an X-Acto knife will fix that problem.
Alan, KØBG
www.k0bg.com
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Protecting Modular Plugs from Breakage
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by W5LL on June 16, 2008
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I always thought those boots where there to protect the tab on the RJ-45 from hanging on other wires and possibly breaking off when you have to pull it back through a bunch of cabling.
W5LL
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RE: Protecting Modular Plugs from Breakage
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by KB8ASO on June 16, 2008
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On the Lindy website:
This product has been discontinued.
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Protecting Modular Plugs from Breakage
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by K5END on June 16, 2008
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Good points.
Note also that there are some specialized variances on the RJ-45 type plugs, and are known by slightly different names. For example, some are made for flat cable vs round, or some are "keyed" to prevent insertion into the wrong jack. Some of the plugs actually are sold in pieces and require assembly before crimping (this helps for custom pinouts.)
The good crimpers have removable dies for the various plugs. It is quite an investment to be able to crimp your own--unless you or someone you know works with these tools routinely.
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Protecting Modular Plugs from Breakage
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by KZ1X on June 16, 2008
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Don't forget, the 8P8C plug (the correct terminology) comes in several different **CONTACT** types as well, because the requirements are different for stranded, solid, and foil-type wires.
If you use the wrong one for the mic wire you have, the contact will either not work, be mechanically prone to fail, or be intermittent.
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RE: Protecting Modular Plugs from Breakage
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by TMTYLER357 on June 16, 2008
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Just a side note. I hope you remember that these connectors are for RJ-45 connectors like the ones on a Cat5 ethernet networking cable. If you are trying to use these on the new mic connectors that are like a telephone connector. Those connectors are RJ-11 connectors and they are smaller than the RJ-45 connectors.
RJ-45 connectors have 8 pins
RJ-11 connectors have 6 pins
Chances are the boots referred to are going to be a tiny bit bigger than they should be.
Sorry if I ruined any ideas. I'd hate to see someone spend money on something that may not work.
73,
Tyler
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RE: Protecting Modular Plugs from Breakage
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by TMTYLER357 on June 16, 2008
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Well, I'm pretty sure RJ-11 connectors have six but, I could be wrong. I do know that RJ-45 has 8 pins though.
I just took a look at my phone cable and if a phone cable has RJ-11 connectors (which I believe it is), it has 6 pins. I have a FT-7800R and it has a connector with 6 pins, so I assume it is an RJ-11 connector.
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RE: Protecting Modular Plugs from Breakage
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by KI4US on June 16, 2008
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http://www.lindy-usa.com/post-assembly-rj-45-male-strain-relief-boot-black-10-per-pack/60385.html
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RE: Protecting Modular Plugs from Breakage
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by KC2RGW on June 16, 2008
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Yeah I confused the 4 connections with 6 vs 4 positions.
RJ22 4P4C handset cord
RJ11 6P4C line cords (common for mics)
RJ25 6P6C
RJ45 8P8C 'ethernet cable' (mics and data)
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RE: Protecting Modular Plugs from Breakage
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by KB1LKR on June 16, 2008
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The common telephone "POTS" (Plain Old Telephone Service) plugs and jacks have 6 contact positions. When wired as a Registered Jack of type RJ-11 (technically a wiring configuration not the jack itself) only 2 wires (center pair) are used -- or the second pair is used for power to light a dial light, such as used on the Princess phones.
Four wires (two lines) is RJ-14, all six wires is an RJ-25, though all use the same 6 position connector.
It would be nice if radios shipped w/ overmolded (or slide on) strain reliefs w/ the ears (or a cover) to prevent latching tab snags though, and in spite of the remarks above, everyone (myself included!) calls them RJ-11's and RJ-45's.
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Protecting Modular Plugs from Breakage
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by K1CJS on June 16, 2008
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I've got an Icom V8000, and have been plugging and unplugging the mike from the radio right along, as I usually park in a lease garage for my job, the car has to be left with the ignition key so they can move it around if need be. The tab hasn't broken in four years of use.
However, I've also got an Icom IC2700H, and the tab did break off of that connector--because it got caught and pulled back. It didn't break right away--it took a little time.
Bottom line? Take care of your equipment, try not to let accidents happen, and it will last. Although the connectors aren't as robust as the old fashioned ones, they are strong enough to do the job.
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Protecting Modular Plugs from Breakage
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by TANAKASAN on June 16, 2008
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What would really help are modular plugs with METAL tabs instead of plastic. I've been searching for plugs like this for years and never found them. Any clues?
Tanakasan
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RE: Protecting Modular Plugs from Breakage
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by KA1OS on June 16, 2008
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Those who worry about breaking the tabs on their modular plugs could create an adapter to another connector type designed for repeated plugging.
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Protecting Modular Plugs from Breakage
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by KB2HSH on June 16, 2008
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This subject is LITERALLY right up my ally, seeing as how I am a PBX Technician for a living. (I'm glad someone else knew the difference between RJ-11 and RJ-14!)
That being said, to extend the mic on my FT-817, I used nothing more than a Cat 6 patch cord, with an 8-COnductor coupler. Works great, and leaves the plugging/unplugging duties to a throw away, rather than a keeper.
John KB2HSH
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Protecting Modular Plugs from Breakage
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by N3KQX on June 16, 2008
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Yaesu MH-59 mic has a molded sleeve over the tab already. In fact, it is much larger than the connector, so I think it might offer a good bit of protection, and provides the proper illusion of water resistance.
http://flickr.com/photos/n3kqx/2585536400/
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Protecting Modular Plugs from Breakage
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by KE4CXP on June 16, 2008
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Here is a link for the connector boots an rj-45 plugs.
http://www.lindy-usa.com/cables/connectors/network/
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A State of Confusion
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by N4CQR on June 17, 2008
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----------------
RJ-45 connectors have 8 pins
RJ-11 connectors have 6 pins
RJ11 is four pin isn't it and RJ25 is six?
Well, I'm pretty sure RJ-11 connectors have six but, I could be wrong
Don't forget, the 8P8C plug (the correct terminology) comes in ......
RJ22 4P4C handset cord
RJ11 6P4C line cords (common for mics)
RJ25 6P6C
RJ45 8P8C 'ethernet cable' (mics and data)
(I'm glad someone else knew the difference between RJ-11 and RJ-14!)
------------------
That's funny I don't care who you are....
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RE: A State of Confusion
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by K0BG on June 17, 2008
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Let's burst a bubble here. The RJ (Registered Jack) is one form of a M O D U L A R jack, and they use specific plugs. Some plugs are for flat ribbon (Silver Satin) wire, and some for round wire. They may be 2, 4, 6, or 8 conductors depending on the application.
The plugs are N O T the same as those used for CAT-5 cables, Icoms, Yaesus, etc. Yes, they plug in to the jacks meant for other types of connections, but that doesn't mean they are the same animal. In fact, there are about 45 different configurations, with 6 different types of crimps.
The tools for crimping them are also different. Yes, you can gerry-rig a mic cable using a silver satin telephone plug, or a CAT 5 plug, and crimp them with a Radio Shack plastic telephone crimping tool. That in itself doesn't mean much.
One of the reasons modular jacks get such a bad rap from the amateur community it just for the reason stated above (gerry-rigging). However, using the correct plug for the application at hand, and applying them with the correct tool, they are very secure and work very well.
As for the cost of the jacks versus a standard 8 pin mic connectors; look up the last column (bulk) pricing, and you'll see they are nearly identical in cost. The main reason they are used nowadays is due to their physical size, and the fact the jacks can be flow soldered during assembly. And believe it or not, those various mic plugs are inserted and crimped by a machine!
Alan, KØBG
www.k0bg.com
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Protecting Modular Plugs from Breakage
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by KB3REV on June 17, 2008
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I simply used a razor blade and cut a boot off an existing cat5 cable and was able to slip it over my homemade head unit extension cable for my FTM-10R which uses a rj45 connector.
I cut a slit in the boot along one of the mold lines on just one side of the boot. It could then easily come off the cat5 and go on the radio's cable. Of course, now it's split & needs to be secured.
I secured it with a couple nylon cable ties, one on the cable to prevent it slippong up, and one on the lower body of the boot itself, making sure it wouldn't interfer with clipping/unclipping the plug.
Not pretty, but works fine and protects the clip. The only cost was just my time...
I'd guess that if you could find out what solvent would weld the boot back together, it's be cheap AND pretty, but cheap and ugly suits me just fine.
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Protecting Modular Plugs from Breakage
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by K0RGR on June 17, 2008
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When I got my IC-2720H some years ago, I was disturbed by the terrible quality of the construction of the RJ-cable that connects the main body to the control head. The outer jacket of the cable was stripped off a good 1/2" away from the crimp-on connector, meaning that the whole assembly dangles there by the tiny wires that attach it.
To improve things, I applied a drop of clear silicone rubber sealant to the back of the plug, and along the cable back to beyond where the vinyl jacket ended, creating a decent strain relief that's still working several years and a couple cars later.
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Protecting Modular Plugs from Breakage
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by VA3SAX on June 17, 2008
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I would beg to differ with your opinion that they are only really good for one connection. In the networking lab we often connect a cable several times in a single session and there are multiple labs per day using the same equipment. I'd also like to know what the difference is between typical RJ45s and the mic plugs...it's used rj45s to connect to the mic plug and they work perfectly fine
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RE: Protecting Modular Plugs from Breakage
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by WB9JTK on June 17, 2008
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I should have the "post assembly" boots back in stock (black only) June 25.
http://www.secondhandradio.com/ShowAd.aspx?id=210
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RE: Protecting Modular Plugs from Breakage
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by KJ5XX on June 18, 2008
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Tyler wrote " I hope you remember that these connectors are for RJ-45 connectors like the ones on a Cat5 ethernet networking cable. If you are trying to use these on the new mic connectors that are like a telephone connector. Those connectors are RJ-11 connectors and they are smaller than the RJ-45 connectors."
Very true Tyler - the connectors I was referring to are the RJ-45 type, not the (smaller) RJ-11 type 6 pin type (compare an ethernet connector to a phone connector if you want to see the difference).
Good point, however, important to know which type your radio uses before you buy.
Haven't checked to see if they make a similar boot for the RJ-11 type (but I haven't seen these on any of my rigs).
73,
Ron - KJ5XX
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RE: Protecting Modular Plugs from Breakage
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by LEER66 on June 19, 2008
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I purchased a package of the protectors from Lindy and they arrived today. They go easily on my Icom 706 MKIIG mike plug and leave about 3/8 inch of the plug sticking out past the protector so there is no interference when inserting the plug. They should do an adequate job of protecting the cord from premature breakage due to overflexing at the joint. You could do the same thing with a couple of turns of self-bonding rubber tape. My beef was the postage. The pack of 10 protectors was about $5 and was quite small. I asked for the least expensive shipping, like a small envelope, but they arrived in a large catalog envelope, with the Lindy catalog, with a $4.75 postage cost. So that makes them about a $1 each. I suppose skipping one burger, fries, and Coke will not doubt cover the shipping cost and I'll still have some good protectors left. I recommend the protectors if you want a very professional looking setup, otherwise I'd go with the tape next time.
Bob KE5KDT
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Protecting Modular Plugs from Breakage
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by KB0WZY on June 21, 2008
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I'd like to offer some information with regard to building your own modular connectors. I've worked in the telecom profession since the mid 1980's and have had the opportunity to see many innovations in technology.
For years, we used a modular crimper manufactured by General Tool Corp, a very fine (i.e. expensive) tool with interchangeable dies for 4-pin, 6-pin, and 8-pin modular plugs. After getting the individual wires sorted into the proper order, they had to be trimmed to a specific length, inserted and crimped.
Then along came an innovative tool called an "EZ-RJ45". You no longer needed to cut the wires to that specific length to get a proper termination; you could leave the wires as long as you wanted to assure that they were both fully inserted and in the proper order before crimping. The connectors allowed the individual wires to completely pass-through, and a blade on the tool would cut them off when you squeezed the handle to crimp. A virtually perfect crimp every time.
http://www.iautomate.com/10004b.html
IMPORTANT: In order to take advantage of the "EZ" feature of the tool, you must purchase "EZ-RJ45" or "EZ-RJ11" plugs.
The Pro tool cuts the wire on both the 6-pin and 8-pin connectors, and the Standard tool cuts the wires on only the 8-pin connectors.
The 6-pin crimper die does all variations of 6-PIN modular plugs, i.e. 2-wire, 4-wire and 6-wire; the only difference is the number of pins manufactured in the modular plug. To my knowledge, there is no "EZ-RJ22" (RJ-22 a.k.a. handset plug) version commonly available.
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Protecting Modular Plugs from Breakage
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by N3PZZ on June 22, 2008
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RJ-45 connectors are just plain junk, period...........
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