1. LEAR Terminals & Connectors
Product presentation
MKR Plus - MKS Plus
Ø4.0 mm cavity

2. Introduction 1. Product 2. Extraction tool 3. Product description
4. Application reports
5. Technical specification
6. Environmental simulation
7. Chemical resistance
8. Documentation summary
9. Benefits
24 August 2005

3. 1. Product - Terminals MKR Plus terminal FLR-cable 0.75 – 1.50 sqmm
MKS Plus terminal
FLR-Cable
0.75 – 1.50 sqmm
24 August 2005

4. 1. Product - Seals Single cable seal FLR-Cable 0.75 – 1.50 sqmm
Cavity plug
24 August 2005

5. 1. Product - Housings 2-way housing Adaptor
2-way housing with convolute tubing support
3-way housing
Adaptor
3-way housing
24 August 2005

6. 1. Product - Housings 4-way housing Adaptor
4-way housing with convolute tubing support
6-way housing
Adaptor
6-way housing with convolute tubing support
24 August 2005

7. 1. Product - Housings 5-way housing
All housings have secondary lock keeper bars
4- or 6-way sealing cap
2-way sealing cap
24 August 2005

8. 1. Product MKR/ MKS Plus ø 1.5 mm Contact principle
Primary lock made from stainless steel
Spring supported contact fingers
2.Contact zone
1.Contact zone
Steel cage
Contact points
24 August 2005

9. 2. Extraction tool MKR Plus / MKS Plus
part number:
24 August 2005

10. 3. Product description
The MKR Plus is a 1.5 mm spring supported socket. It has a box-
section and is designed for crimping with single cable seals.
The MKS Plus is a 1.5 mm spring supported pin for connecting to
the MKR Plus socket. It has a box-section and is designed for
crimping with single cable seals.
Operational usages:
High vibration systems in accordance with the requirements of
Suitable for high vibration usage on chassis‘, engines, axles
and gearboxes
DIN 72585
24 August 2005

11. 3. Product description Terminal materials Metal Base material CuSn4
Spring X12 CrNi 17 7
Plating
— Sn thickness 2 to 4 µm
Area 1: inner gal Ni 2 + gal Sn 2+2
Area 2: both sides gal Ni 1
Area 3: both sides gal Ni 1 + gal Sn 1.5
24 August 2005

12. 3. Product description Pitch size : 4.5 mm x 4.5 mm for part numbers:
26780
25701
24 August 2005

13. The available specifications cover the following points:
4. Application reports
The available specifications cover the following points:
• Implementation style
• Performance characteristics
• Testing
24 August 2005

14. 5. Technical Specification
Current carrying
Contact resistance
Continuous temperature requirements
Insulation resistance
Terminal retention force in a housing
Maximum pin angle
Terminal cross-section
Engagement and withdrawal forces
Crimp measurements
Crimp tensile strength
Vibration requirements
Contact disconnection
Climate test
Water sealing
Thermal testing
Dynamic testing
24 August 2005

15. Derating without housing
5.1 Current carrying
Derating without housing
MKR - MKS Plus 0.50 / 0.75 / 1.00 mm²
Material: CuSn Plating: Sn
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Current I [A]
Component temperature tu [°C]
0.50 mm²
0.75 mm²
1.00 mm²
24 August 2005

16. Derating without housing
5.1 Current carrying
Derating without housing
MKR - MKS Plus 1.50 / 2.50 mm²
Material: CuSn Plating: Sn
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Current I [A]
Component temperature tu [°C]
1.50 mm²
2.50 mm²
24 August 2005

17. Material: CuSn Plating: Sn
5.1 Current carrying
Derating in housing
MKR - MKS Plus 0.75 mm²
Material: CuSn Plating: Sn
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Current I [A]
Component temperature tu [°C]
24 August 2005

18. Material: CuSn Plating: Sn
5.1 Current carrying
Derating in housing
MKR - MKS Plus 1.00 mm²
Material: CuSn Plating: Sn
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Current I [A]
Component temperature tu [°C]
24 August 2005

19. Material: CuSn Plating: Sn
5.1 Current carrying
Derating in housing
MKR - MKS Plus 1.50 mm²
Material: CuSn Plating: Sn
35.0
30.0
25.0
20.0
15.0
10.0
5.0
0.0
Current I [A]
Component temperature tu [°C]
24 August 2005

20. 5.2 Contact resistance R
A value of 5 mΩ must not be exceeeded for a new connection.
After testing to DIN 72585, a value of 10 mΩ must not be exceeded
24 August 2005

21. 5.3 Continuous temperature requirements
Plating Sn
The maximum continuous operating temperature for this terminal plating is ° C.
Connection cycles: maximum 20
Plating Au (available by special request)
The maximum continuous operating temperature for this terminal plating is ° C, which is limited by the terminal base material.
Connection cycles: maximum 100
24 August 2005

22. 5.4 Insulation resistance
High voltage test
A test voltage of Ueff=1000 V, 50 or 60 Hz was applied over a minimum period of one minute across a set of terminals as well as between every other terminal and the outside of the housing with no shorting or carbonisation appearing.
The measured insulation resistance was greater than 107
Measurement of the leakage current between adjacent terminals
24 August 2005

23. 5.5 Terminal retention force
Primary
Terminal primary lock without housing secondary lock
Material PA , PBT without glass filling
> 60 N
Secondary
Housing secondary lock without terminal primary lock
Material PA , PBT without glass filling
> 60 N
24 August 2005

24. 5.6 Maximum pin angle Terminal pin Ø 1.5 +0,05
Maximum central mis-alignment 0.25
1.5° maximum allowable pin angle
24 August 2005

25. 5.7 Terminal cross-section
2. Contact zone
5.05
2.6
1. Contact zone
24 August 2005

26. Material: CuSn Plating: Sn
5.8 Engagement force
MKR - MKS Plus
Results over 10 cycles
Material: CuSn Plating: Sn
Engagement force 16 14 12 10 8 6 4 2
F [N]
Cycle
Maximum
Average
Minimum
24 August 2005

27. Material: CuSn Plating: Sn
5.8 Withdrawal force
MKR - MKS Plus
Results over 10 cycles
Material: CuSn Plating: Sn
Withdrawal force 14 12 10 8 6 4 2
F [N]
Cycle
Maximum
Average
Minimum
24 August 2005

28. 5.9 Crimp measurements MKR Plus
Part number
Nominal CSA
Crimp sizes
Crimp sizes
Wire crimp mm
Insulation crimp mm
26780
0.75 sqmm
Height : 1.20
3.60
Width :
3.50
26780
1.00 sqmm
Height : 1.25
3.70
Width :
3.50
26780
1.50 sqmm
Height :1.35
3.70
Width :
3.60
Example - wire crimp
Example - Insulation crimp ( sealed )
Insulation claw
Seal H H B
Copper cable B
Cable insulation
24 August 2005

29. 5.9 Crimp measurements MKS Plus
Part number
Nominal CSA
Crimp sizes
Crimp sizes
Wire crimp mm
Insulation crimp mm
25701
0.75 sqmm
Height :1.20
3.60
Width :
3.50
25701
1.00 sqmm
Height :1.25
3.70
Width :
3.50
25701
1.50 sqmm
Height :1.35
3.70
Width :
3.60
Example - wire crimp
Example - Insulation crimp ( sealed )
Insulation claw
Seal H H B
Copper cable B
Cable insulation
24 August 2005

30. 5.10 Crimp tensile strength
Fmin
Only wire crimp,
without insulation crimp
Nominal CSA Cable construction ( FLR ) Force
0.75 sqmm strand x Ø 0.22 mm Fmin > 80 N
1.00 sqmm strand x Ø 0.24 mm Fmin > 100 N
1.50 sqmm strand x Ø 0.30 mm Fmin > 140 N
* Measured by Lear T&C
24 August 2005

31. 5.11 Vibration requirements
Tests with connected housings,
For full description see DIN , March 1996
Test group C
Visual check
Contact resistance
Vibration requirements with free-standing
connected terminals, gradient K2:
30g, 3-way axis for 50h at ambient and 120°C,
supported at 100 mm
contact disconnection: t<1s, R<7 R 7
1 Metal support
2 Connected to current supply
3 Cable
4 Free-standing connector
5 Vibration table
6 Free-standing connector
7 Joined to vibration table R
24 August 2005

32. 5.12 Contact disconnection
During the total vibration test time of 300 hours, the contact resistance should not be :
>7 Ω for longer than 1 μs R
24 August 2005

33. 5.13 Climate test R R Climate tests with connected housings
For full description see DIN , March 1996
Test group K
Visual check
Contact resistance
Insulation resistance
Humidity change
21 days humidity change to DIN FW24:
23°C/40°C, 83% / 92% rel.H, 1 cycle=24h
Temperature change
50 cycles, gradient K2, - 40°C / +140°C
Contact resistance, Insulation resistance, Visual check R R
24 August 2005

34. 5.14 Water sealing Water sealing ( IP 9K ),
Tests with connected housings
For full description see DIN , March 1996
Test group L
Visual check
Insulation resistance
Water sealing IP9K
DIN Part 9, high pressure
jet wash
Jet wash and spray distribution for test equipment to certify protection against high pressure water ingress - Water gradient 9K
24 August 2005

35. 5.15 Thermal testing Temperature / Running time
MKR - MKS Plus 1.00 mm²
Tests in housings - 1-way equipped / 1-way nominal current
( 20.0 A )
Material: CuSn Plating: Sn
Temperature [°C]
Time [sec]
24 August 2005

36. 5.15 Thermal testing Temperature / Running time
MKR - MKS Plus 2.50 mm²
Tests in housings - 1-way equipped / 1-way nominal current
( 27.5 A )
Material: CuSn Plating: Sn
Temperature [°C]
Time [sec]
24 August 2005

37. 5.16 Dynamic testing 120 Temperature [° C ] 23 / +-5 23 50 10050
100
Time [ h ]
There should be no interuption of the current flow during the test
24 August 2005

38. 6. Environmental simulation
Protection against dust penetration:
In accordance with DIN and DIN , a dust mist was created from 50% limestone and 50% pulverised ash. Approximately 2kg of this dust was placed in the test chamber per m³ volume and this suspension was maintained during the test as required.
Conclusion:
Protection against dust penetration was in accordance with the specification.
Industrial climate:
In accordance with DIN and EN ISO 6988, three cycles of 72h in an atmosphere of condensation, sulphur dioxide and humidity were carried out, with a sulphur dioxide density of 2.0 per m³ each cycle.
Conclusion :
Protection against corrosion was in accordance with the specification.
Protection from salt spray
In accordance with DIN and DIN SS, the test was carried out over 90h with a concentrated test solution spray of 50
+/-5g sodium chloride.
Protection against salt spray was in accordance with the specification.
24 August 2005

39. 7. Chemical resistance
For this test, the samples were sprayed for 5s with each of the
chemicals listed below and then connected for 24h at 80°C.
Diesel fuel to DIN EN 590
Fuel mixture (70% Diesel and 30% FAM test liquid to
DIN B and DIN )
Motor oil, SAE 30 to DIN 51511
Brake fluid to DIN ISO 4925
Antifreeze
Transmission oil, SAE 80W-90 to DIN 51512
Conclusion:
Protection against these chemicals was in accordance with
the specification
24 August 2005

40. 8. Documentation summary
Lear T&C - specifications:
GHW-WN Construction rules for open,
uninsulated crimped terminals
GHW-WN Test rules for crimped connectors,
general requirements and
processing rules
Special specifications:
DIN K2 Version
DIN IEC Version
DIN EN ISO Version
DIN Version 1993
Applicable regulations, typically standards
24 August 2005

41. 9. Benefits
MKR Plus / MKS Plus is a proven design with over four years in service with Volvo Trucks, MAN and Scania
Proven quality record over this period
Potential cost savings when compared to competitor parts
Lear T&C technical and after-sales support
Lear Corporation worldwide support
Possibilities to develop new products using this terminal system in the future
Parts available for larger cavity diameters Excellent housing designs – see Truck Catalogue
24 August 2005