How to wire and crimp an RJ45 connector

The RJ-45 connector has been used in strain measurement systems for many years, almost two decades. 

This type of connector can provide a very stable, low-labor method for connecting large numbers of strain gages. 

However, if certain details are neglected, the connection can cause frustration.  Unlike the digital networks for which the RJ-45 is designed, strain gages do not offer error checking, send/receive acknowledgement, and won’t resend missing data! 

Fortunately, achieving good quality connections with RJ-45 connectors is easy if you follow these rules:

  1. Use stranded, 26-AWG cable into the RJ-45.This type of cable will fill the connector channel with plenty of strands for the crimp pin to seat in the center of the strands.

  2. Use an RJ-45 connector that is designed for stranded wire.Some RJ-45 are designed for solid-conductor wire, others are designed for stranded wire.

  3. Use an RJ-45 connector that has gold-plated contacts and crimp pins.These provide the most stable and connection and the least possible contact resistance.

  4. And perhaps most important, use a high quality crimping tool.Some low-cost tools do not press the crimp pins on the connector well into the cable strands.


Crimping RJ45 Connectors (Video):










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Kevin Swiger

United States