Draft 1.0 of SP-3-0235-RV1 (TIA-1096-A)

TIA
STANDARD

Telecommunications

Telephone Terminal Equipment

Connector Requirements for
Connection of Terminal Equipment to
the Telephone Network

TIA-1096-A

March 2008

TELECOMMUNICATIONS INDUSTRY ASSOCIATION

Representing the telecommunications industry in
association with the Electronic Industries Alliance

ANSI/TI A-1096-A

Approved: March 17, 2008

Adopted by ACTA
May 6, 2008

PREFACE

This document, TIA-1096-A,

Telecommunications – Telephone Terminal Equipment – Technical

Requirements for Connection of Terminal Equipment to the Telephone Network,

has been

established pursuant to the Federal Communication Commission’s (“FCC”) Report and Order in
the 2000 Biennial Review of Part 68 of the Commission’s Rules and Regulations, CC Docket No.
99-216, FCC 00-400, adopted November 9, 2000 and released December 21, 2000 (“Order” or
“R&O”). The Order privatized the process by which technical criteria for the prevention of harm
are established for customer premises or terminal equipment that may be sold for connection to
the telephone network, and for the approval of such equipment to demonstrate compliance with
the relevant technical criteria. The Order directed the industry to establish the Administrative
Council on Terminal Attachments (“ACTA”) as the balanced and open body that would assume
the Commission’s Part 68 role for those items privatized in the Order (Section 68.602). This
document was created for submission to ACTA by the TIA Working Group TR-41.9.1

Subcommittee TR-41.9, Technical Regulatory Considerations. It is intended to fulfill the FCC’s
requirement to establish technical criteria for Telephone Terminal Equipment.

Notice of Disclaimer and Limitation of Liability

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(From Standards Proposal No. 3-

0235-RV1

, formulated under the cognizance of the

TIA, TR

-41

User Premises Telecommunications Requirements

. TR-

41.9

Subcommittee on

Technical and Administrative Regulatory Considerations

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TIA-1096-A

Table of Contents

SCOPE AND APPLICATION ..........................................................................................1

1.1

COPE

......................................................................................................................1

1.2

PPLICATION

.............................................................................................................1

1.3

MPLEMENTATION

ATES

...........................................................................................1

NORMATIVE REFERENCES..........................................................................................1

DEFINITIONS AND ACRONYMS ...................................................................................2

PHYSICAL REQUIREMENTS.........................................................................................2

4.1

ENERAL

..................................................................................................................2

4.2

NITS OF

EASURE

..................................................................................................3

...................................................................................3

4.3.1

Miniature 6-Position Plug.....................................................................................4

4.3.2

Miniature 6-Position Jack ..................................................................................11

4.3.3

Miniature 8-Position Plug, Unkeyed: .................................................................14

4.3.4

Miniature 8-Position Series Jack .......................................................................21

4.3.5

50-Position Miniature Ribbon Plug ....................................................................24

4.3.6

50-Position Miniature Ribbon Jack ....................................................................29

4.3.7

3-Position Weatherproof Plug............................................................................33

4.3.8

3-Position Weatherproof Jack ...........................................................................34

4.3.9

Miniature 8-Position Plug, Keyed ......................................................................35

4.3.10

Miniature 8-Position Keyed Jack .......................................................................42

CONTACT REQUIREMENTS .......................................................................................45

..........................................................................................45

5.1.1

Gold Surface Layer............................................................................................45

5.1.2

Nickel Barrier Layer ...........................................................................................45

............................................................45

5.2.1

Sample Selection...............................................................................................46

5.2.2

Mating and Unmating Forces Test ....................................................................46

5.2.3

Durability Test....................................................................................................46

5.2.4

Contact Resistance ...........................................................................................47

5.2.5

Temperature and Humidity Cycling Test ...........................................................48

5.2.6

Mixed Flowing Gas Test ....................................................................................49

WIRING CONFIGURATIONS........................................................................................49

ANNEX A (Informative) – MODIFIED SO

TEST METHOD ............................................... 50

ANNEX B (Normative) – MIXED FLOWING GAS TEST..................................................... 51

TIA-1096-A

FOREWORD

(This foreword is not part of this Standard.)

The requirements concerning mechanical characteristics and dimensions of the plug and
jack connectors described in this document were originally contained in Subpart F of
Part 68 of the Federal Communication Commission (FCC) Rules. When the
Commission created the Administrative Council for Terminal Attachments (ACTA) in
Report & Order FCC 00-400 on CC Docket No. 99-216, it turned over responsibility for
maintaining most of the technical criteria in Part 68 to industry. In compliance with one
of the provisions of that Report & Order, the Telecommunications Industry Association
(TIA) created Interim Standard IS-968 to provide an initial set of technical criteria
identical to that which then existed in Part 68. Thus, the Part 68, Subpart F connector
requirements were included in TIA IS-968 that was adopted by the ACTA in 2001. In
2002, TIA IS-968 was superseded by TIA-968-A, which was also adopted by the ACTA.

The original Part 68, Subpart F specifications included requirements that 6-position and
8-position modular connector contacts provide a hard gold to hard gold interface, or
equivalent, when a plug and jack were mated. In Docket No. 88-57, the FCC requested
the Electronic Industries Alliance (EIA) to develop a procedure for demonstrating the
equivalency of alternative contact materials to hard gold. In 1989, TIA Subcommittee
TR-41.9 included such a procedure in its Telecommunications Systems Bulletin EIA/TIA
TSB-31 on suggested Part 68 test methods.

In its work to revise TSB-31-B, TR-41.9 was reminded that TSBs are intended to provide
guidance, not contain mandatory requirements. However, separating the test procedure
from the requirements for determining the hard gold equivalence of alternative contact
materials proved extremely challenging. A solution was found by removing the
requirements concerning mechanical characteristics and dimensions of the plug and jack
connectors from TIA-968-A and combining them with test procedures and requirements
for hard gold and alternative contact materials from TSB-31-B into this new standard,
TIA-1096.

An error was found in Figures 4-29 and 4-30 of TIA-1096 after it had been approved and
submitted to ACTA for adoption. Although the figures were identified as showing an 8-
position keyed plug, they actually depicted an un-keyed plug. Further checking found
this error first occurred in IS-968 and had continued to be perpetuated. This revision of
TIA-1096 corrects that error by properly depicting an 8-position keyed plug as originally
shown in Subpart F of Part 68.

This standard was produced by Subcommittee TR-41.9, Technical and Administrative
Regulatory Considerations. It was developed in accordance with ANSI and TIA
procedural guidelines and represents the consensus position of the Subcommittee,
which served as the formulating group. It has also received the concurrence of
Engineering Committee TR-41, User Premises Telecommunications Requirements.

iii

TIA-1096-A

Subcommittee TR-41.9 acknowledges the written contributions and leadership provided
by the following individuals to the development of this standard:

Organization

Representative

Previous

Version

TIA-1096-A

Littelfuse Phillip

Havens

Chair

Mitel Greg

Slingerland

Chair

–

VTech Steve

Whitesell Editor

Editor

Sprint Cliff

Chamney

–

Thomson Roger

Hunt

–

Verizon Trone

Bishop

Suggestions for improvement of this standard are welcome. They should be sent to:

Telecommunications Industry Association

Engineering Department

Suite 300

2500 Wilson Boulevard

Arlington, VA 22201

TIA-1096-A

1 SCOPE AND APPLICATION

1.1 S

COPE

The technical criteria in this standard are intended to protect the telephone network from
the harms defined by the Federal Communications Commission (FCC) Part 68, Section
3 rules in Title 47 of the Code of Federal Regulations (47 CFR 68.3). This standard
specifies physical dimensions, mechanical characteristics, and contact material
requirements for:

1. Carrier-installed jacks used at the demarcation point in accordance with 47 CFR

68.105(a);

2. Plugs and jacks used with inside wiring in accordance with 47 CFR 68.213(b);

3. Plugs and jacks used to connect terminal equipment to wireline carrier networks.

This standard outlines test methods for determining compliance with the requirements
for hard gold contacts. Additionally it outlines a test method for determining equivalency
to hard gold plating performance for alternative contact materials.

1.2 A

PPLICATION

Two categories of specifications are used in this standard, mandatory requirements and
recommendations. Mandatory requirements are designated by the words "shall" and
“shall not” and recommendations by the words "should" and “should not”.

The notes to figures in clause 4 of this document contain mandatory requirements.

This standard was specifically developed for submission to the Administrative Council for
Terminal Attachments (ACTA). It is intended to supersede the technical criteria in
clause 6.1 of TIA-968-A and the criteria that clause references in clause 15 and
Appendices D and E of TIA-TSB-31B.

Testing of connectors for compliance with this standard should be carried out under
normal laboratory conditions of 20°C to 25°C and 20% to 60% relative humidity unless
otherwise specified.

1.3 I

MPLEMENTATION

ATES

The criteria in this revision of the standard may be applied to terminal equipment
approved after publication of this document (TIA-1096-A) by the ACTA.

The criteria in this revision of the standard shall be applied to terminal equipment
approved 6 months after publication of this document (TIA-1096-A) by the ACTA.

2 NORMATIVE REFERENCES

The following standards contain provisions, which, through reference in this text,
constitute provisions of this standard. At the time of publication, the editions indicated
were valid. All standards are subject to revision, and parties to agreements based on this

TIA-1096-A

standard are encouraged to investigate the possibility of applying the most recent
editions of the standards indicated below. ANSI and TIA maintain registers of currently
valid national standards.

1. ASTM

E384-05a,

Standard Test Method for Microindentation Hardness of Materials

2. EIA-364-09C-1999,

Durability Test Procedure for Electrical Connectors and Contacts

3. EIA-364-13B-1998,

Mating and Unmating Forces Test Procedures for Electrical

Connectors

4. EIA-364-53B-2000,

Nitric Acid Vapor Test, Gold Finish Test Procedure for Electrical

Connectors and Sockets

5. IEC 60512-2-1,

Connectors for Electronic Equipment – Tests and Measurements –

Part 2-1: Electrical Continuity and Contact Resistance Tests – Test 2a: Contact
Resistance – Millivolt Level Method

6. T1.TR.5-1999,

Network and Customer Installation Interface Connector Wiring

Configuration Catalog

3 DEFINITIONS AND ACRONYMS

For the purposes of this standard, the following definitions apply.

go gauge:

a gauge whose dimensions are such that the object being tested will be

accepted.

hard gold:

An alloy consisting primarily of pure gold with a small amount of a hardening

agent such as cobalt or nickel.

mating force:

The peak in-line force measured during insertion of a plug into its

associated jack up to the point where the latching tab locks the plug in place.

no-go gauge:

a gauge whose dimensions are such that the object being tested will not

be accepted.

unmating force:

The peak in-line force measured during removal of a plug from its

associated jack with the latching tab unlocked from the jack.

4 PHYSICAL REQUIREMENTS

4.1 G

ENERAL

The plugs and jacks described in this section represent the standard connectors to be
used for connections to the telephone network. The plug and jack designs shown are
representative of generic types, and should not be interpreted as the only designs that
may be used. Design innovation and improvement is anticipated; but for
interchangeability to be maintained, alternative designs shall be compatible with the
plugs and jacks shown.

Hardware used to mount, protect, and enclose standard jacks is not described. The only
requirement on connecting blocks, housings, dust covers, outdoor boxes, and the like
that contain standard network jacks is that they shall accept standard plugs with
cordage.

TIA-1096-A

For special purpose applications, plugs may be made longer than shown or adapted for
direct use on equipment or apparatus without cordage. The sliding modular plug used
on the back of many modular wall telephone sets is an example of such a special
purpose application. It is the responsibility of the designers and manufacturers of
communication equipment who use such plugs to assure that they are compatible with
the hardware used to mount standard jacks with which they plan to interface.

4.2 U

NITS OF

EASURE

US customary units were the original dimensional units used in designing the plugs and
jacks specified by this document and are shown in parentheses throughout this section.
The dimensions shown without parenthesis are in SI (Système International) units (i.e.
the International System of measurement).

The SI dimensional units are derived from the US customary units by multiplying inches
by 25.4 to derive the exact conversion in millimeters with no rounding-off of the resulting
decimal value. The number of decimal places to which the conversion is taken is
governed by the concept that when the calculated SI dimensional unit is divided by 25.4,
the resulting inches calculation will be exactly that shown in the parenthesis (the original
design dimension).

The conversion to SI force units, Newtons (N), is rounded off to a number of decimal
places that will result in the calculated SI force value being within less than 1% of the
original US customary force unit value located adjacent in parenthesis (the original
design value). The rationale for this is to bring the force conversions to within the
degree of accuracy of the force-measuring device and avoid the carrying of an
unrealistic number of decimal places that would otherwise result from an exact
conversion.

4.3 I

NDIVIDUAL

LUGS AND

ACKS

The figures and corresponding notes in the following subclauses contain the mechanical
and dimensional requirements for several different types of connectors. If alternative
designs are used, the interface dimensions between mating plugs and jacks shall be
maintained.

Where a hard gold to hard gold contact is specified, the hard gold surface shall meet the
requirements of 5.1. Where an alternative to hard gold contact material is allowed, the
contact material shall be compatible with hard gold contacts meeting the requirements of
5.1 and shall provide equivalent contact performance as specified in 5.2.

TIA-1096-A

Figure 4-3: 6-Position Plug Mechanical Specification (continued)

NOTES to Figures 4-2 and 4-3:

1. All plugs shall be capable of meeting the requirements of the go and no-go

gauges shown in Figures 4-5 and 4-6.

2. Section BB applies to any jack contact receiving slot that does not contain a plug

contact.

3. The major cordage cross section should be 2.5400 mm (0.100 in) max. thick by

5.0800 mm (0.200 in) max. wide, with rounded corners. It should exit the plug on
the plug centerline. Other cordage configurations are permitted but may inhibit
the special features of some network jack enclosures.

4. The standard plug length shall be 11.6840 mm (0.460 in) max. Plugs may be

made longer than standard or adapted for direct use on special cords, adapters
without cordage, and on apparatus or equipment. Plugs longer than standard
could inhibit the special features of some network jack enclosures. It is the
responsibility of the designers and manufacturers of communication equipment
who use such plugs to assure that they are compatible with the hardware used to
mount standard jacks with which they plan to interface.

5. A 12.0396 mm (0.474 in) minimum tab length shall be required. A maximum tab

length should be no longer than 13.2080 mm (0.520 in). Longer tabs may be
used with the same limitations as described in Note 4 to Figures 4-2 and 4-3.

6. To obtain maximum plug guidance when 6-position plugs are inserted in 8-

position jacks, the front plug nose should be extended to the 2.3368 mm (0.092
in) maximum.

7. These dimensions shall apply to the location of jack contact receiving slots. Plug

contacts should be centered axially in these slots.

TIA-1096-A

NOTES to Figure 4-4:

1. The plug/jack contact interface shall be hard gold to hard gold (see 5.1) and shall

have a minimum gold thickness of 1.2700 µm (50 µin) on each side of the
interface. Alternative contact material that is compatible with hard gold and
provides equivalent contact performance may be used under certain conditions
(see 5.2). The minimum contact force at the interface shall be 0.98 N (100 g). A
smooth, burr-free surface shall exist at the interface in the area shown. Contact
surface roughness shall be 0.8128 µm (32 µin) maximum. Compliance can be
determined by observation with 10X magnification. Compare surface protrusions
and burrs on the contact surface with a 32-µin, ground-surface-finish gauge.

2. The jack contact design is based upon 0.4572 mm (0.018 in) spring temper

phosphor bronze round wire in the modular plug blade and jack contact interface.
Other contact configurations that provide contact performance equal to or better
than the preferred configurations and do not cause damage to the plug or jack
are permitted. The jack contact width should be 0.44958/0.49530 mm
(0.0177/0.0195 in). Deviations from the preferred jack contact width are
permitted for round contacts as well as noncircular cross sectional shapes but
they shall be compatible with existing plug configurations. The requirements of
Note 1 to Figure 4-4 shall apply to all possible contact areas.

3. The configuration of the plug contact and the front plastic of the plug shall

prevent jack contacts from being damaged during plug insertion into jacks.

4. This nominal contact angle should be provided between plugs and jacks with the

plug latched into the jack. This angle shall be less than 24° to avoid loss of
electrical contact between the plug and jack. The nominal contact angle shall be
greater than 13° to avoid interference between jack contacts and the internal
plastic in the plug.

5. To avoid loss of electrical contact, the dimension from datum B to the highest

point ‘‘X’’ should be 5.0800 mm (0.200 in) max. A dimension greater than 5.3594
mm (0.211 in) could result in loss of electrical contact between plugs and jacks.
The 5.3594 mm (0.211 in) max. shall be considered an absolute maximum.

6. The 24° min. angle applies only to plugs with front plastic walls higher than

4.8260 mm (0.190 in).

TIA-1096-A

breakout strength.

2. Surface Z need not be planar or coincident with the surface under the plug

release catch. Surface Z projections shall not prevent insertion, latching, and
unlatching of the standard 6-position plug of 4.3.1.

3. The indicated plug stop surface should be used. If some other internal feature is

used as a plug stop, it shall be located so that the axial movement of a latched
plug is no greater than 1.1430 mm (0.045 in).

4. To prevent mistargeting between the plug and jack contacts, the jack contacts

shall be completely contained in their individual contact zones, 0.7112 mm (0.028
in) max. wide, where they extend into the jack openings. There is no location
requirement for jack contacts below these zones 5.8420 mm (0.230 in) max., but
adequate contact separation shall be maintained to prevent electrical breakdown.
These shaded contact zones shall be centrally located, (included all locating
tolerances), about the jack opening width 9.8806 mm (0.389 in) Ref, (Datum -W-
). Contacts located outside of these zones could result in mistargeting between
the jack and plug contacts.

5. All inside and outside corners in the plug cavity shall be 0.3810 mm (0.015 in)

radius max. unless specified.

6. These surfaces shall have 0°15’ maximum draft.

7. Relief inside the dotted areas on 3 sides of the jack opening is permitted. The

6.8326 mm (0.269 in) Ref and 9.8806 mm (0.389 in) Ref Gauge Requirements
shall be maintained in each corner, (ref. 1.0160 mm (0.040 in) min), to assure
proper plug/jack interface guidance. There shall be a 0.8128 ± 0.1270 mm
(0.032 ± 0.005) relief on the top side (opposite plug catch) on jacks in
connecting blocks which mount and connect portable wall telephones so as to
assure interface with the special purpose sliding modular plug used on many wall
telephone sets.

8. 4.0640 mm (0.160 in) and 6.5278/6.8580 mm (0.257/0.270 in) dimensions shall

be centrally located to jack opening width -W- within ± 0.1778 mm (± 0.007 in).

9. Minimum acceptable jack contact length. When contact guide slots are used, the

contacts shall always be contained inside the guide slots and the contacts shall
move freely in the slots so as not to restrain plug insertion or damage jack
contacts.

10. Gauge Requirements:

a. GO: The jack shall be capable of accepting a 9.7536 mm x 6.7056 mm

(0.3840 in x 0.2640 in) gauge and the gauge shall be capable of being
removed with a maximum force of 8.9 N (2 pounds).

b. NO GO: The jack shall not accept either a 10.00760 mm x 6.45160 mm

(0.3940 in x 0.254 in) horizontal width of opening gauge or a 6.95960 mm x
9.5504 mm (0.2740 in x 0.376 in) vertical height of opening gauge. However,
if either gauge is accepted the force necessary to remove the gauge shall be
minimum 0.83 N (3.0 ounces).

c. Removal force requirements shall not include forces contributed by contact

springs nor shall external forces be applied to the jack that will affect these
removal forces.

TIA-1096-A

Figure 4-11: 8-Position Unkeyed Plug, Mechanical Specification (continued)

NOTES to Figures 4-10 and 4-11:

1. All plugs shall be capable of meeting the requirements of the plug go and no-go

gauges shown in Figures 4-13 and 4-14.

2. The standard plug height in the area shown shall be 8.0010 mm (0.315 in)

maximum. The standard plug length shall be 23.1140 mm (0.910 in) maximum.
Plugs may be made longer than standard or adapted for direct use on special
cords, adapters without cordage, apparatus or equipment. Plugs longer and/ or
higher than standard could inhibit the special features of some network jack
enclosures. It is the responsibility of the designers and manufacturers of
communication equipment who use such plugs to assure that they are
compatible with the hardware used to mount standard jacks with which they plan
to interface.

3. A 14.6050 mm (0.575 in) minimum tab length shall be provided. The maximum

tab length should be no longer than 15.8750 mm (0.625 in). Longer tabs may be
used with the same limitations described in Note 2 to Figures 4-10 and 4-11.

4. To obtain maximum plug guidance in jacks, the front plug nose should be

extended to the 2.3368 mm (0.092 in) maximum.

5. These dimensions shall apply to the location of jack contact receiving slots. Plug

contacts should be centered axially in these slots.

6. The center rib centerline shall be coincident with the plug width 11.6840 mm ref.

(0.460 in ref.) centerline within

0.0762 mm (

0.003 in).

TIA-1096-A

NOTES to Figure 4-12:

1. The plug/jack contact interface shall be hard gold to hard gold (see 5.1) and shall

2. The jack contact design is based upon 0.4572 mm (0.018 in) spring temper

phosphor bronze round wire in the modular plug blade and jack contact interface.
Other contact configurations that provide contact performance equal to or better
than the preferred configurations and do not cause damage to the plug or jack
are permitted. Contact width should be 0.44958/0.49530 mm (0.0177/0.0195 in).
Deviations from the desirable jack contact width are permitted for round contacts
as well as noncircular cross sectional shapes but they shall be compatible with
existing plug configurations. The requirements of Note 1 to Figure 4-12 shall
apply to all possible contract areas.

3. The configuration of the plug contact and the front plastic of the plug shall

prevent jack contacts from being damaged during plug insertion into jacks.

4. This nominal contact angle should be provided between plugs and jacks with the

plug latched into the jack. This angle shall be equal to or less than 24° to avoid
loss of electrical contact between the plug and jack. The nominal contact angle
shall be equal to or greater than 13° to prevent interference between jack
contacts and the internal plastic in the plug.

5. To avoid loss of electrical contact, the dimension from datum B to the highest

6. The 24° min. angle shall apply only to plugs with front plastic walls higher than

4.8260 mm (0.190 in).

TIA-1096-A

4. To prevent mistargeting between the plug and jack contacts, the jack contacts

shall be completely contained in their individual contact zones, (0.7112 mm
(0.028 in) max. wide), where they extend into the jack openings. There is no
location requirement for jack contacts below these zones (5.8420 mm (0.230 in)
max.), but adequate contact separation shall be maintained to prevent electrical
breakdown. These shaded contact zones shall be centrally located, (include all
locating tolerances), about the jack opening width 11.9126 mm (0.469 in) Ref,
(Datum -W-). Contacts located outside of these zones could result in
mistargeting between the jack and plug contacts.

5. All inside and outside corners in the plug cavity shall be 0.3810 mm (0.015 in)

radius max. unless specified.

6. These surfaces shall have 0°15’ maximum draft.

7. Relief inside the dotted areas on both sides of the jack opening is permitted. The

6.8326 mm (0.269 in) Ref and 11.9126 mm (0.469 in) Ref Gauge Requirements
shall be maintained in each of the corners indicated, (Ref. 1.5240 mm (0.060 in)
min), to assure proper plug/jack interface guidance.

8. 4.0640 mm (0.160 in) and 6.2992 mm (0.248 in) dimensions shall be centrally

located to jack opening width -W- within ± 0.1270 mm (0.005 in).

9. The contact lengths shall be such that the contacts will always be contained

inside the guide slots, and the contacts shall move freely in the slots so as not to
restrain plug insertion or damage jack contacts.

10. Gauge Requirements:

a. GO: The jack shall be capable of accepting an 11.7856 mm x 6.7056 mm

(0.4640 in x 0.2640 in) gauge and the gauge shall be capable of being
removed with a maximum force of 8.9 N (2.0 pounds).

b. NO GO: The jack shall not accept either a 12.0396 mm x 6.4516 mm (0.4740

in x 0.254 in) horizontal width of opening gauge or a 6.9596 mm x 11.5824
mm (0.2740 in x 0.456 in) vertical height of opening gauge. However, if the
gauge is accepted, the force necessary to remove the gauge shall be a
minimum of 0.83 N (3.0 ounces).

c. Removal force requirements do not include forces contributed by contact

springs nor shall external forces be applied to the jack that will affect these
removal forces.

d. Gauges shall have a 0.7620 mm (0.030 in) radius on the nose and a 0.3810

mm (0.015 in) radius on all edges with clearance provided for contacts.

11. With no plug inserted, conductors 1 and 4 shall be bridged as well as conductors

5 and 8. With a miniature 8-position plug inserted into the jack, the bridge
connectors shall be broken and a series connection shall be made in both sides
of the line. With a 6-position plug inserted, the bridged connections shall remain
unbroken.

12. The jack contact/bridging interface shall be hard gold to hard gold (see 5.1) and

shall have a minimum gold thickness of 1.2700 µm (50 µin) on each side of the
interface. Alternative contact material that is compatible with hard gold and
provides equivalent contact performance may be used under certain conditions
(see 5.2). The minimum hard gold contact bridging force shall be 0.294 N (30 g).

TIA-1096-A

NOTES to Figures 4-18, 4-19 and 4-20:

1. Contact finish in the region of contact shall be gold, 0.7620 µm (30 µin) minimum

thickness, and should be electrodeposited hard gold.

2. ‘‘Datum B’’ shall be the center line of contact cavities.

3. The center line of each contact shall be located within 0.2286 mm (0.009 in) of

true position with respect to ‘‘Datum B’’.

4. Contact width at region of contact shall be (1.143 ± 0.0508) mm (0.04 ± 0.002 in).

5. Center line of shell dimension indicated shall be within 0.1270 mm (0.005 in) of

‘‘Datum B’’.

6. Center line of barrier dimension indicated shall be within 0.1270 mm (0.005 in) of

‘‘Datum B’’.

7. ‘‘Surface X’’ shall have a 0.1016 µm (4 µin) finish or better; finishing shall be

done in the direction of the arrow.

8. A force of not more than 178 N (40 pounds) shall be sufficient to fully insert the

plug onto the sizing gauge shown on Figure 4-18. The plug is fully inserted when
‘‘Surface A’’ of the plug touches ‘‘Surface A’’ of the sizing gauge.

9. After one insertion of the plug on the sizing gauge, Figure 4-19, a force of not

more than 44.5 N (10 pounds) shall be sufficient to fully insert the plug on the
continuity gauge shown in Figure 4-20. The plug is fully inserted on the
continuity gauge when ‘‘Surface A’’ of the plug touches ‘‘Surface A’’ of the
continuity gauge.

10. When the plug is fully inserted on the continuity gauge, Figure 4-20, after having

been inserted once on the sizing gauge, Figure 4-19, all contacts of the plug shall
electrically contact the continuity gauge as determined by an electrical continuity
test which applies an open circuit voltage of not more than 10 Volts. Results
greater than 200

indicate test failure.

TIA-1096-A

NOTES to Figures 4-22, 4-23 and 4-24:

1. Contact finish in the region of contact shall be gold, 0.7620 µm (30 µin) minimum

thickness, and should be electrodeposited hard gold.

2. ‘‘Datum B’’ shall be considered the center line of contact cavities.

3. The center line of each contact shall be located within 0.2286 mm (0.009 in) of

true position with respect to ‘‘Datum B’’.

4. Contact width at region of contact shall be 1.1430± 0.0508 mm (0.045±0.002 in).

5. Center line of shell dimension indicated shall be within 0.1270 mm (0.005 in) of

Datum B’’.

6. Center line of cavity dimension indicated shall be within 0.1270 mm (0.005 in) of

Datum B’’.

7. ‘‘Surface X’’ shall have a 0.1016 µm (4 µin) finish or better; finishing shall be

done in the direction of the arrow.

8. A force of not more than 134 N (30 pounds) shall be sufficient to fully insert the

jack onto the sizing gauge shown on Figure 4-23. The jack is fully inserted when
‘‘Surface A’’ of the jack touches ‘‘Surface A’’ of the sizing gauge.

9. After one insertion of the jack on the sizing gauge, Figure 4-23, a force of not

more than 44.5 N (10 pounds) shall be sufficient to fully insert the jack on the
continuity gauge shown in Figure 4-24. The jack is fully inserted on the continuity
gauge when ‘‘Surface A’’ of the jack touches ‘‘Surface A’’ of the continuity gauge.

10. When the jack is fully inserted on the continuity gauge, Figure 4-24, after having

been inserted once on the sizing gauge, all contacts of the jack shall electrically
contact the continuity gauge as determined by an electrical continuity test which
applies an open circuit voltage of not more than 10 volts. Results greater than
200

indicate test failure.

TIA-1096-A

NOTES to Figures 4-29 and 4-30:

1. All plugs shall meet the requirements of the plug go and no-go gauges shown in

Figures 4-32 and 4-33.

2. The standard plug height in the area shown shall be 8.0010 mm (0.315 in)

3. The minimum tab length shall be 14.6050 mm (0.575 in). The maximum tab

length normally shall be no longer than 15.8750 mm (0.625 in). Longer tabs may
be used with the limitations described in Note 2 to Figures 4-29 and 4-30.

4. To obtain maximum plug guidance in jacks, the front plug nose should be

extended to the 2.3368 mm (0.092 in) maximum.

5. These dimensions apply to the location of jack contact receiving slots. Plug

contacts should be centered axially in these slots.

6. The center rib centerline shall be coincident with the plug width, 11.6840 mm ref

(0.460 in ref.) center line within ± 0.0762mm (± 0.003 in)

TIA-1096-A

NOTES to Figure 4-31:

1. The plug/jack contact interface shall be hard gold to hard gold (see 5.1) and shall

have a minimum gold thickness of 1.2700 µm (50 µin) on each side of the
interface. Alternative contact material that is compatible with hard gold and
provides equivalent contact performance may be used under certain conditions
(see 5.2). The minimum contact force at the interface shall be 0.98 N (100 g). A
smooth, burr-free surface shall exist at the inter-face in the area shown. Contact
surface roughness shall be 0.8128 µm (32 µin) maximum. Compliance can be
determined by observation with 10X magnification. Compare surface protrusions
and burrs on the contact surface with a 32-µin, ground-surface-finish gauge.

2. The jack contact design is based upon 0.4572 mm (0.018 in) spring temper

phosphor bronze round wire in the modular plug blade and jack contact interface.
Other contact configurations that provide contact performance equal to or better
than the preferred configurations and do not cause damage to the plug or jack
may be provided. The jack contact width normally shall be 0.44958/0.49530 mm
(0.0177/0.0195 in). Deviations from the preferred jack contact width are
permitted for round contacts as well as noncircular cross sectional shapes but
such deviations shall be compatible with existing plug configurations. The
requirements of Note 1 to Figure 4-31 shall apply to all possible contact areas.

3. The configuration of the plug contact and the front plastic of the plug shall

prevent jack contacts from being damaged during plug insertion into jacks.

4. This should be the nominal contact angle between plugs and jacks with the plug

latched into the jack. This angle shall be equal to or less than 24° to avoid loss
of electrical contact between the plug and jack. The nominal contact angle shall
be equal to or greater than 13° to avoid interference between jack contacts and
the internal plastic in the plug.

5. To avoid loss of electrical contact, the dimension from “Datum B” to the highest

point “X” should be 5.0800 mm (0.200 in) max.  A dimension greater than 5.3594
mm (0.211 in) could result in loss of electrical contact between plugs and jacks.
The 5.3594 mm (0.211 in) max. shall be considered an absolute maximum.

6. The 25° min. angle shall apply only to plugs with front plastic walls higher than

4.8260 mm (0.190 in).

TIA-1096-A

FIGURE 4-31

4-17

Figure 4-35: 8-Position Keyed Jack, Mechanical Specification

NOTES to Figure 4-35:

1. Front surface projections beyond the 1.3970 mm (0.055 in) minimum shall be

configured so as not to prevent finger access to the plug release catch
(Reference Figure 4-30, 8-Position Plug, Mechanical Specifications). A catch
length should be greater than 1.3970 mm (0.055 in) to provide greater breakout
strength and improved guidance when interfacing with a 6-position plug.

2. Surface Z need not be planar or coincident with the surface under the plug

release catch. Surface Z projections shall not prevent insertion, latching, and
unlatching of the keyed 8-position plug of 4.3.9.

3. The indicated plug stop surface should be provided. If some other internal

feature is used as a plug stop, it shall be located so that the axial movement of a
latched plug is no greater than 1.1430 mm (0.045) in.

4. To prevent mistargeting between the plug and jack contacts, the jack contacts

TIA-1096-A

shall be completely contained in their individual contact zones 0.7112 mm (0.028
in) max wide, where they extend into the jack openings. There is no location
requirement for jack contacts below these zones (5.8420 mm (0.230 in) max), but
adequate contact separation shall be maintained to prevent electrical breakdown.
These shaded contact zones shall be centrally located, (include all locating
tolerances), about the jack opening width 11.9126 mm (0.469 in) Ref, (Datum–
W–). Contacts located outside of these zones could result in mistargeting
between the jack and plug contacts.

5. All inside and outside corners in the plug cavity shall be 0.3810 mm (0.015 in)

radius max unless specified.

6. These surfaces shall have 0°15' maximum draft.

7. Relief inside the dotted areas on both sides of the jack opening shall be

permitted. The 6.8326 mm (0.269 in) Ref and 11.9126 mm (0.469 in) Ref Gauge
Requirements shall be maintained in each of the corners indicated, (Ref. 1.5240
mm (0.060 in) min), to assure proper plug/jack interface guidance.

8. 4.0640 mm (0.160 in) and 6.2992 mm (0.248 in) dimensions shall be centrally

located to jack opening width –W– within ± 0.1270 mm (± 0.005 in).

9. The contact lengths shall be such that the contacts will always be contained

inside the guide slots and the contacts shall move freely in the slots so as not to
restrain plug insertion or damage jack contacts.

10. Gauge Requirements:

a. GO: The jack shall be capable of accepting an 11.78560 x 6.70560 mm

(0.4640 x 0.2640 in) gauge and the gauge shall be capable of being removed
with a maximum force of 8.9 N (2.0 pounds).

b. NO GO: The jack shall not accept either a 12.03960 x 6.4516 mm (0.4740 x

0.254 in) horizontal width of opening gauge or a 6.95960 x 11.5824 mm
(0.2740 x 0.456 in) vertical height of opening gauge. However, if the gauge is
accepted, the force necessary to remove the gauge shall be a minimum of
0.83 N (3.0 ounces).

c. Removal forces shall not include forces contributed by contact springs nor

shall external forces be applied to the jack that will affect these removal
forces.

d. Gauges shall have a 0.7620 mm (0.030 in) radius on the nose and a 0.3810

mm (0.015 in) radius on all edges with clearance provided for contracts.

TIA-1096-A

5 CONTACT REQUIREMENTS

5.1 H

ARD

OLD

ONTACTS

Note: The hard gold contact requirements in this clause are not intended
to limit the contact interface to one that is produced by a plating process.

5.1.1 Gold Surface Layer

The gold surface layer in the specified contact interface area shall meet the following
requirements:

1. The material content shall be 99% pure gold minimum.

2. The material density shall be 17 grams/cm

minimum.

3. The minimum gold thickness in the specified interface area shall be

a. 1.2700 µm (50 µin) for 6 and 8 position connectors, or

b. 0.7620 µm (30 µin) for 50 position connectors.

4. The Knoop microindention hardness value shall be between 130 and 250 when

measured in accordance with ASTM E384-05a using a load force of 0.245 N
(25 g).

5. Test specimens shall exhibit no corrosion products having a diameter greater

than 0.05 mm (0.002 in) when tested for porosity and other surface defects per
EIA-364-53B.

5.1.2 Nickel Barrier Layer

A nickel barrier layer shall be used between the gold surface layer and the base metal.
It shall meet the following requirements:

1. The material content shall be 99.5% pure nickel minimum, and no other single

component shall be more than 0.2%.

2. The minimum nickel thickness shall be 1.2700 µm (50 µin).

3. The nickel barrier layer shall not crack when a contact sample is bent through a

180° angle, with the plated surface away, around a mandrel whose diameter is
equal to the thickness or diameter of the contact sample.

5.2 C

ONTACTS

SING

LTERNATIVE

ATERIALS

Alternative contact materials may be used for 6 and 8 position connectors provided they
are compatible with hard gold contacts as specified in 5.1 and meet the equivalent
performance requirements specified in this clause.

An alternative contact material shall be defined by a specification and shall meet all of its
documented design requirements. The specification shall have sufficient detail to allow
a competent independent laboratory to verify that the alternative material contact system
complies with the design requirements. An inadequate interface specification, one that
is too general or omits necessary information, is reason for rejecting the proposed
alternative material interface.

TIA-1096-A

5.2.1 Sample

Selection

For evaluation purposes, samples of both plugs and jacks for both hard gold and
alternative contact interface systems are required. The samples of alternative contact
interface systems shall include, in addition to the proposed new alternative contact
system, samples of all alternative contact systems previously shown to be equivalent to
the hard gold contacts defined in 5.1.

The hard gold contact interface samples shall meet the requirement for a gold contact
interface as defined in 5.1. Test samples should have gold plating thicknesses as close
as practical to the 1.2700 µm (50 µin) minimum permissible thickness. No connector
contacts with more than 1.5240 µm (60 µin) thick gold shall be used to evaluate
alternative contact materials.

Alternative material contact samples representative of production units shall be selected
so that the physical parameters of the test sample parts are on the side of the tolerance
that would produce the least favorable test results. (An example would be the selection
of parts with minimum plating thickness to produce minimum expected durability results.)

All sample plugs and jacks shall meet the relevant mechanical and dimensional
requirements described in 4.3.

5.2.2 Mating and Unmating Forces Test

The mating and unmating forces test shall be performed in accordance with EIA-364-
13B. Mating and unmating of the plug and jack shall be at a rate of 10mm/s (0.4 in/s).
The following test procedure shall be used:

(a) Select at least ten plug and jack sample pairs of each type for testing (e.g. 6-

position/6-conductor or 8-position/8-conductor connector).

(b) Insert plug into jack until latching tab locks.

(d) Insert plug into jack until latching tab locks and measure mating force.

(e) Remove plug from jack by depressing latching tab and measure unmating force.

(f) Repeat step (b) and step (c) for 49 more cycles.

(g) Repeat steps (d) and step (e).

The maximum mating force for each of the 10 samples shall not exceed 17.6 N (1.8 kg)
and the maximum unmating force shall not exceed 7.35 N (0.75 kg).

5.2.3 Durability

Test

The durability test shall be performed in accordance with EIA-364-09C. The following
test procedure shall be used:

(a) Select at least fifteen plug and jack sample pairs of each type for testing with a

minimum of 60 contacts for each material combination.

(b) Perform 250 mating/unmating cycles with a minimum interval between cycles of

5 s. Mating and unmating of the plug and jack shall be at a rate of 10 mm/s (0.4
in/s).

barrier plating systems, the modified sulfur dioxide (SO

) test method described

TIA-1096-A

in Annex A should be used. Another approved chemical test method is the Nitric
Acid Vapor Test per EIA-364-53B. For other types of barrier plating systems, test
methods applicable for the type of material should be used.

(d) When observed with 10x magnification, no more than 10% of the contacts tested

shall be broken through in the wear track as indicated by products generated by
the chemical reaction.

5.2.4 Contact

Resistance

The contact resistance shall be determined before and after subjecting samples of
connectors to the temperature and humidity cycling test of 5.2.5 and the mixed flowing
gas test of 5.2.6. The following test procedure shall be used:

(a) Select two sets of connector samples with at least 80 total contacts in each set

(i.e., a total of 160 contacts). All contacts in a particular plug-jack combination
shall be tested.

(b) Precondition both sets of samples by performing five mating and unmating

cycles. These preconditioning cycles are to be performed at 20

C +2

C, with no

cleaning of the contacts permitted.

Figure 5-1, by calculation or by measurement, for all contact pairs.

(d) Determine the bulk resistance of the free connector between points B and C in

Figure 5-1, by calculation or by measurement, for all contact pairs.

(e) Measure the total mated connector resistance between points A and C in Figure

5-1, following the requirements and procedures of IEC 60512-2-1 for all contact
pairs.

(f) Calculate the contact resistance by subtracting the sum of the bulk resistances of

the fixed and free connectors from the total mated connector resistance for all
contact pairs.

Contact resistance = R

- (R

+ R

)

(g) Subject one set of connector samples to the temperature and humidity cycling

test of 5.2.5.

(h) Subject the other set of connector samples to the mixed flowing gas test of 5.2.6.

(i) Repeat steps (c) through (f) for both sets of samples.

(j) Determine the change in contact resistance by subtracting the initial resistance

from the final resistance for each contact pair.

(k) For each set of samples, determine the average change in resistance for the four

contact pairs that experience the greatest resistance increase.

The initial contact resistance shall not exceed 20 milliohms for any contact pair.

The average change in resistance for the four contact pairs with the greatest change in
resistance as a result of the temperature and humidity cycling test of 5.2.5 shall not
exceed 15 milliohms.

The average change in resistance for the four contact pairs with the greatest change in
resistance as a result of the mixed flowing gas test of 5.2.6 shall not exceed 10
milliohms.

TIA-1096-A

FREE CONNECTOR

Figure 5-1: Contact Resistance Connections

5.2.5 Temperature and Humidity Cycling Test

Perform temperature and humidity cycling as follows:

(a) Without disturbing the connector contact points after the initial contact resistance

measurement in step (f) of 5.2.4, place one set of connector samples in a
temperature and humidity chamber.

(b) Cycle the chamber through the following test conditions:

1. 30 minutes at 32° C (90° F) and 90% relative humidity;

2. Two hour transition to -40

C (-40

F) and any reasonable humidity;

3. 30 minutes at -40

C (-40

F) and any reasonable humidity;

4. Two and one-half hour transition to 66° C (150° F) and 15% relative humidity;

5. 30 minutes at 66° C (150° F) and 15% relative humidity;

TIA-1096-A

6. Two-hour transition back to 32° C (90° F) and 90% relative humidity.

are to be subjected to a total of 50 temperature and humidity cycles).

(d) Allow 30 minutes for the samples to stabilize at room ambient temperature and

humidity conditions. The connectors shall not be moved or contact points
disturbed during this time.

Remeasure the contact resistance and determine the amount of resistance change as
described in steps (i) through (k) of 5.2.4.

5.2.6 Mixed Flowing Gas Test

The following procedure shall be used:

(a) Without disturbing the connector contact points after the initial contact resistance

measurement in step (f) of 5.2.4, place one set of connector samples in a
suitable environmental test chamber.

(b) Perform mixed flowing gas test as described in Annex B.

Remeasure the contact resistance and determine the amount of resistance change as
described in steps (i) through (k) of 5.2.4.

6 WIRING CONFIGURATIONS

The connectors specified in this standard shall be wired in accordance with any of the
applicable wiring configurations provided in T1.TR.5-1999.

TIA-1096-A

ANNEX A (Informative) – MODIFIED SO

TEST METHOD

The modified sulfur dioxide (SO

) test procedure consists of the following steps:

(1)

Wash samples in distilled water.

(2)

Rinse samples in isopropyl alcohol.

(3)

Allow samples to air dry (not blown).

(4)

Place 100 ml of sulfurous acid in a 10-liter desiccator and allow to stand for 30
minutes.

(5)

Suspend samples in chamber for 24 hours at ambient temperature without
touching solution.

(6)

After exposure, dry samples at 80

C for 10 minutes.

(7)

Prepare saturated dimethylglyoxime (DMG) solution in ethanol.

(8)

Mix one part of above with one part concentrated ammonium hydroxide.

(9)

Apply mixture of Step (h) to samples. The solution should completely wet
samples by aerosol spraying, immersion, or swabbing.

(10) Allow samples to air dry (not blown).

(11) Nickel exposure is indicated by a pink colored corrosion product.

NOTE: After drying, white crystals on surface are dried DMG. Nickel
will show as a pink colored corrosion product while base metal would
have shown as a corrosion product after exposure to sulfurous acid.

TIA-1096-A

ANNEX B (Normative) – MIXED FLOWING GAS TEST

B.1 G

ENERAL

In the evaluation of contact interfaces for gold equivalency, it is necessary to evaluate
the contact interface performance when exposed to a corrosive atmosphere. A
corrosive atmosphere is best simulated by a mixed flowing gas test. Since such a test
has not yet been standardized, it is necessary to include a complete mixed flowing gas
test procedure in this Document.

The procedure selected is based upon Project TP-65 draft text developed by EIA
Engineering Committee P5.1 and is representative of the type of test being conducted by
the connector industry at present. If a procedure for mixed flowing gas testing is
standardized, it will be considered for use in replacing this annex

B.1.1 Content

This annex covers the test procedure for producing environmentally related corrosive
atmospheres to determine the reaction of plated or unplated surfaces when exposed to
different concentrations of flowing gas mixtures.

B.1.2 Description

Samples which are to be evaluated may be mated or unmated connectors, components,
or experimental materials. They are placed in an environmentally controlled chamber
that is monitored by a gas analyzing system for controlled concentrations of the gas
mixture. Corrosion rates are monitored by silver and copper control coupons placed in
the chamber for each test. These control coupons are removed and analyzed using
calometric reduction for factors related to amount and type of corrosive product growth
to confirm severity control level.

B.1.3 Safety

This procedure involves the use of hazardous materials, operations, and equipment.
This annex does not purport to address all of the safety concerns that may be
associated with its use. It is the responsibility of the user of this annex to consult and
establish appropriate safety and health practices and determine the applicability of
regulatory limitations prior to use. For specific precautions, see B.4.

B.2 M

ATERIALS

(1) Control Coupons

(a) Copper sheet, oxygen free high conductivity, UNS C10200, 0.0127 mm

(0.005 inch) thick, temper 0.5 hard.

(b)

Silver foil, pure fine grain, 0.0127 mm (0.005 inch) thick.

(c)

Acid, sulfuric, concentrated, AR grade.

(d) Jewelers

Rouge.

(e)

1,1,1 Trichloroethane, AR grade.

TIA-1096-A

(f)

Deionized or distilled water.

(g)

Hydrochloric Acid, AR grade.

(h)

Methanol, AR grade.

(2) Exposure Materials

(a)

Nitrogen gas, pro-purified grade or better.

(b)

Nitrogen dioxide gas, chemically pure grade or better.

(c)

Hydrogen sulfide gas, chemically pure grade or better.

(d)

Chlorine gas, chemically pure grade or better.

(e)

Clean, dry and oil-free air.

(f)

Gas injection equipment, for example, Teflon permeation tubes.

B.3 T

EST

QUIPMENT

(1) Coupon Evaluation Equipment

(a) Coulometric

Analyzer

Coulometry for IMFG monitoring is limited to determination of sulfide and
oxide films on copper, and sulfide and chloride films on silver. Experience
has shown that monitoring these films is usually sufficient to validate the
IMFG environmental conditions of the chamber.

(b) Weight

gain

equipment

NOTE: provided correlation with coulometric method has been
demonstrated.

(2) Environmental Chamber

(a) The environmental chamber is to consist of an enclosure made of

noncorrosive, nonmetallic materials contained within a cabinet, oven, or
incubator capable of maintaining the temperature within the specified
ranges, see Table B-1. A commercially available environmental chamber
will suffice.

(b)

The constant temperature chamber for permeation tubes, if used, is to be
capable of controlling the temperature within +1

C over a temperature

range of 15-30

(3) Source of clean dry air

(4) Appropriate gas analysis equipment for calibrating and monitoring the gas

concentrations in the chamber. The gas analysis equipment is to be capable of
the following accuracy:

Total

Sulfur

Analyzer

+1 ppb at 20% upper range limit

+4 ppb at 80% upper range limit

Analyzer

+1 ppb at 20% upper range limit

+4 ppb at 80% upper range limit

TIA-1096-A

Analyzer

+4%

(5) Temperature and humidity monitoring equipment, capable of an accuracy of

±0.5° C and ±1% relative humidity, respectively.

B.4 S

AFETY AND

EALTH

ONSIDERATIONS

Do not perform these procedures unless the operator is fully trained in handling
hazardous materials and knowledgeable of the appropriate precautions necessary to
perform this test. Appropriate safety and health representatives should be consulted for
any other prerequisites or proper procedures prior to performing this specification. The
safety and environmental procedures to observe include, but are not limited to, the
following items:

(1) Material Safety Data Sheets with first aid information have been obtained for all

chemicals used both in cleaning and testing.

(2) The operator has received the Safety Sheets and become familiar with normal

precautions for handling corrosive and toxic materials.

(3) All necessary safety equipment is available including a properly functioning, well

lighted fume hood, eyewash station/shower, large sink with running water, acid
resistant glove and apron, chemical goggles and acid spill kit.

(4) All chemicals have been properly labeled and will be properly stored in

accordance with Occupational Safety and Health Administration (OSHA) and
Environmental Protection Agency (EPA) Regulations.

(5) Arrangements for proper storage and disposal of chemicals have been made.

B.5 S

AMPLE

REPARATION

B.5.1 Control Coupon Preparation

This is a critical process in conducting the test and therefore the same method should be
used each time the test is performed. Improper cleaning may introduce contaminants
that can affect the corrosion rates and mechanisms. The following method has been
found to produce reproducible results.

WARNING!

PERFORM ALL WORK WITH ACIDS, SOLVENTS, OR GASES
IN A FUME HOOD. CHEMICAL GOGGLES, OR FACE SHIELD,
SHALL BE WORN. OBSERVE PRECAUTIONS IN HANDLING
CORROSIVE AGENTS.

(1) Copper

(a)

Vapor degrease with 1,1,1 trichloroethane or equivalent for 1 minute.

(b)

Rinse thoroughly with methanol.

(c)

Rinse thoroughly with deionized or distilled water.

(d)

Etch with 15% solution of sulfuric acid at 50° C for 2 minutes.

(e)

Rinse with deionized or distilled water.

(f)

Dry with clean, dry, filtered air.

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(2) Silver

(a)

Dip in concentrated hydrochloric acid for 2 minutes.

(b)

Rinse with deionized or distilled water.

(c)

Dry with clean, dry, filtered air.

(d)

Buff with jewelers rouge.

(e)

Ultrasonically clean with 1,1,1 trichloroethane or equivalent for 1 minute.

(f)

Repeat cleaning with fresh 1,1,1 trichloroethane.

(g)

Air dry (not blown).

(h)

Vapor degrease with 1,1,1 trichloroethane or equivalent for 1 minute.

(i)

Air dry (not blown).

(j)

Clean cathodically in a boiling solution of trisodium phosphate using an
inert anode for 1 minute at a current of 1.0 ampere.

(k)

Rinse thoroughly with distilled or deionized water.

(l)

Dry with clean, dry, filtered air.

NOTES:

(1)

Control coupons should be handled with clean forceps at all
times with the exception the of buffing in Step (d) above.

(2)

Store coupons in a sealed container that has been filled with
an inert gas (i.e., nitrogen), or an evacuated desiccator until
used.

B.5.2 Test Sample Preparation

Samples are to be tested in the "as received condition" unless otherwise specified. All
surfaces that are not intended for exposure and could influence the various
measurements are to be protected.

B.6 P

ROCEDURE

B.6.1 Calibration

WARNING!

PERFORM ALL WORK WITH ACIDS, SOLVENTS, OR GASES
IN A FUME HOOD. CHEMICAL GOGGLES, OR FACE SHIELD,
SHALL BE WORN. OBSERVE PRECAUTIONS IN HANDLING
CORROSIVE AGENTS.

Prior to the start of a test, all gas concentration monitoring equipment is to be calibrated
by the operator to known standards following procedures outlined by the equipment
manufacturers. After start of the test, the monitoring equipment is to be calibrated at
least every 5 days and on the final day of testing in order to ensure that the readings are
accurate.

NOTE: Some chlorine monitors cannot differentiate between chlorine and
some other pollutant gases. Those monitors will only require calibration
prior to the beginning of testing and just after the final day of testing as

TIA-1096-A

these are the only times that the other gases can be eliminated from the
chamber to allow a determination of the chlorine levels.

B.6.2 Pretest Procedures

(1) Adjust humidity and temperature according to environmental severity class

specified as indicated in Table B-1, without samples in chamber.

(2) Allow chamber to stabilize for temperature and humidity without samples.

Exchange rate is to be adjusted to provide 6 changes per hour.

(3) Currently, chlorine concentration is to be adjusted and stabilized first; this gas

cannot be monitored in combination with the other pollutants.

(4) Figure B-1 defines the zone configuration of a typical test chamber. Control

coupons are to be placed in the shaded zones of Figure B-2. Inert, noncorrosive
materials are to be used for suspending the test samples and control coupons in
the test chamber.

(5) Place samples and control coupons in chamber as soon as possible after

stabilization period. They are to be placed such that there is a minimum space of
5.1 cm (2 inches) between samples, coupons and the chamber walls. Random
placement of the samples at the various measurement intervals throughout the
test is important.

(6) Sample orientation is to be chosen to minimize obstruction of the air flow.

(7) Because of absorption of gases by the samples, allow chlorine concentrations to

stabilize and adjust, if necessary, to the desired concentration.

(8) The remaining pollutants (NO

and H

S) are then to be introduced into the test

chamber and adjusted for the concentrations of the requested exposure class in
Table B-1.

(9) Total reactive corrosion area of samples and control coupons compared to the

volume in inner chamber is to be such that the concentrations of the gasses can
be maintained throughout the test.

Table B- 1: Environmental Severity Limits

Pollutant Concentration (ppb)

Environmental

Class

% Relative

Humidity

Temperature

°C

Discontinued as a test procedure

II 70

+2 30

+2 10

+3 200

+50 10

III 75

+2 30

+2 20

+5 200

+50 100

+20

IV 75

+2 40

+2 30

+5 200

+50 200

+20

TIA-1096-A

B.6.3 Test Procedures

WARNING!

PERFORM ALL WORK WITH ACIDS, SOLVENTS, OR GASES
IN A FUME HOOD. CHEMICAL GOGGLES, OR FACE SHIELD,
SHALL BE WORN. OBSERVE PRECAUTIONS IN HANDLING
CORROSIVE AGENTS.

(1) A recommended exposure time for the test samples is 20 days unless otherwise

specified in the referencing document.

(2) In many cases it may be advantageous to withdraw samples for periodic testing

prior to the full time of the test. After removal from the chamber, such samples
are to be stabilized at ambient room temperature for a minimum of 2 hours,
measured for appropriate response, and returned to the chamber if required.
Such withdrawals are to be noted in the test report.

(3) The interior of the environmental chamber is to be monitored daily for humidity,

temperature, and pollutant concentration. If adjustment is required, additional
monitoring is to be performed. Concentration of chlorine gas is to be adjusted
only at the start of the test and checked at the completion of the test, since
chlorine concentration cannot be analyzed in combination with the other
pollutants. However, the initial chlorine flow rate is to be maintained throughout
the test.

(4) At the conclusion of the test, the test samples is to be removed from the chamber

and stabilized at ambient room temperature for a minimum of 2 hours before
making the final readings or measurements.

B.6.4 Control Coupon Exposures

WARNING!

PERFORM ALL WORK WITH ACIDS, SOLVENTS, OR GASES
IN A FUME HOOD. CHEMICAL GOGGLES, OR FACE SHIELD,
SHALL BE WORN. OBSERVE PRECAUTIONS IN HANDLING
CORROSIVE AGENTS.

(1) A minimum of 3 coupons each of copper and silver, for each time interval and

location in the test chamber, is to be placed in the chamber to monitor corrosion
film growth rates. A minimum of 3 coupons of each type are to be removed after
an exposure time of 48 hours, and a minimum of another 3 coupons of each type
after 95 hours. A new set of coupons are to then be placed in the chamber to
monitor the next major time interval, and again a minimum of 3 coupons of each
type are to be removed after the 48 and 95 hour exposure time.

(2) Recommended major time intervals during a typical 20-day test are as follows:

(a)

between the 1st and 4th day of the test;

(b)

between the 9th and 12th day; and,

(c)

from the 16th through the 20th day.

(3) Control coupons are used to monitor the reaction rate in the chamber and not the

deterioration of the test samples. Coupons removed from the chamber are not to
be returned to the chamber.

TIA-1096-A

(4) Whenever possible, in order to minimize instability of the test conditions within

the chamber, any test samples required to be removed on a certain day is to be
removed at the same time as the control coupons are being removed or
replaced.

B.6.5 Control Coupon Evaluation

Control coupons removed from the chamber are to be analyzed using any method in B.3
to verify chamber conditions.

B.7 D

OCUMENTATION

Data Sheets are to contain:

(1) title of test;

(2) sample description;

(3) test equipment;

(4) number of samples;

(5) test procedure;

(6) actual pollutant concentrations used in the test (H2S, NO2, Cl2);

(7) deviations from test conditions during sample exposure (charts to be supplied if