LEAR Terminals Connectors Product presentation MKR Plus MKS

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LEAR Terminals & Connectors Product presentation MKR Plus - MKS Plus Ø 4. 0

LEAR Terminals & Connectors Product presentation MKR Plus - MKS Plus Ø 4. 0 mm cavity 24 August 2005

Introduction 1. Product 2. Extraction tool 3. Product description 4. Application reports 5. Technical

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 2

1. Product - Terminals MKR Plus terminal FLR-cable 0. 75 – 1. 50 sqmm

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 3

1. Product - Seals Single cable seal FLR-Cable 0. 75 – 1. 50 sqmm

1. Product - Seals Single cable seal FLR-Cable 0. 75 – 1. 50 sqmm Cavity plug 24 August 2005 4

1. Product - Housings 2 -way housing Adaptor 2 -way housing with convolute tubing

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

1. Product - Housings 4 -way housing Adaptor 4 -way housing with convolute tubing

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 6

1. Product - Housings 5 -way housing All housings have secondary lock keeper bars

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

1. Product MKR/ MKS Plus ø 1. 5 mm Contact principle Primary lock made

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 8

2. Extraction tool MKR Plus / MKS Plus part number: 50000. 017. 601 24

2. Extraction tool MKR Plus / MKS Plus part number: 50000. 017. 601 24 August 2005 9

3. Product description The MKR Plus is a 1. 5 mm spring supported socket.

3. Product description The MKR Plus is a 1. 5 mm spring supported socket. It has a boxsection 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 DIN 72585 Suitable for high vibration usage on chassis‘, engines, axles and gearboxes 24 August 2005 10

3. Product description Terminal materials • Metal — Base material Cu. Sn 4 —

3. Product description Terminal materials • Metal — Base material Cu. Sn 4 — Spring X 12 Cr. Ni 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 11

3. Product description Pitch size : 4. 5 mm x 4. 5 mm for

3. Product description Pitch size : 4. 5 mm x 4. 5 mm for part numbers: 26780 25701 24 August 2005 12

4. Application reports The available specifications cover the following points: • Implementation style •

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

5. Technical Specification 6. 1 Current carrying 6. 2 Contact resistance 6. 3 Continuous

5. Technical Specification 6. 1 Current carrying 6. 2 Contact resistance 6. 3 Continuous temperature requirements 6. 4 Insulation resistance 6. 5 Terminal retention force in a housing 6. 6 Maximum pin angle 6. 7 Terminal cross-section 6. 8 Engagement and withdrawal forces 6. 9 Crimp measurements 6. 10 Crimp tensile strength 6. 11 Vibration requirements 6. 12 Contact disconnection 6. 13 Climate test 6. 14 Water sealing 6. 15 Thermal testing 6. 16 Dynamic testing 24 August 2005 14

5. 1 Current carrying Derating without housing MKR - MKS Plus 0. 50 /

5. 1 Current carrying Derating without housing MKR - MKS Plus 0. 50 / 0. 75 / 1. 00 mm² Material: Cu. Sn Plating: Sn 35. 0 30. 0 25. 0 Current I [A] 20. 0 15. 0 10. 0 5. 0 0 20 40 60 80 100 120 140 Component temperature tu [°C] 0. 50 mm² 0. 75 mm² 1. 00 mm² 24 August 2005 15

5. 1 Current carrying Derating without housing MKR - MKS Plus 1. 50 /

5. 1 Current carrying Derating without housing MKR - MKS Plus 1. 50 / 2. 50 mm² Material: Cu. Sn Plating: Sn 35. 0 30. 0 25. 0 Current I [A] 20. 0 15. 0 10. 0 5. 0 0 20 40 60 80 100 120 140 Component temperature tu [°C] 1. 50 mm² 24 August 2005 16

5. 1 Current carrying Derating in housing MKR - MKS Plus 0. 75 mm²

5. 1 Current carrying Derating in housing MKR - MKS Plus 0. 75 mm² Material: Cu. Sn Plating: Sn 35. 0 30. 0 25. 0 Current I [A] 20. 0 15. 0 10. 0 5. 0 0 20 40 60 80 100 120 140 Component temperature tu [°C] 24 August 2005 17

5. 1 Current carrying Derating in housing MKR - MKS Plus 1. 00 mm²

5. 1 Current carrying Derating in housing MKR - MKS Plus 1. 00 mm² Material: Cu. Sn Plating: Sn 35. 0 30. 0 25. 0 Current I [A] 20. 0 15. 0 10. 0 5. 0 0 20 40 60 80 100 120 140 Component temperature tu [°C] 24 August 2005 18

5. 1 Current carrying Derating in housing MKR - MKS Plus 1. 50 mm²

5. 1 Current carrying Derating in housing MKR - MKS Plus 1. 50 mm² Material: Cu. Sn Plating: Sn 35. 0 30. 0 25. 0 Current I [A] 20. 0 15. 0 10. 0 5. 0 0 20 40 60 80 100 120 140 Component temperature tu [°C] 24 August 2005 19

5. 2 Contact resistance R A value of 5 mΩ must not be exceeeded

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 20

5. 3 Continuous temperature requirements Plating Sn The maximum continuous operating temperature for this

5. 3 Continuous temperature requirements Plating Sn The maximum continuous operating temperature for this terminal plating is + 130 ° C. Connection cycles: maximum 20 Plating Au (available by special request) The maximum continuous operating temperature for this terminal plating is + 150 ° C, which is limited by the terminal base material. Connection cycles: maximum 100 24 August 2005 21

5. 4 Insulation resistance High voltage test A test voltage of Ueff=1000 V, 50

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 22

5. 5 Terminal retention force Primary • Terminal primary lock without housing secondary lock

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 23

5. 6 Maximum pin angle Terminal pin Ø 1. 5 +0, 05 Maximum central

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 24

5. 7 Terminal cross-section 2. 6 5. 05 2. Contact zone 1. Contact zone

5. 7 Terminal cross-section 2. 6 5. 05 2. Contact zone 1. Contact zone 24 August 2005 25

5. 8 Engagement force MKR - MKS Plus Results over 10 cycles Material: Cu.

5. 8 Engagement force MKR - MKS Plus Results over 10 cycles Material: Cu. Sn Engagement force 16 Plating: Sn 14 12 F [N] 10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 Cycle Maximum Average Minimum 24 August 2005 26

5. 8 Withdrawal force MKR - MKS Plus Results over 10 cycles Material: Cu.

5. 8 Withdrawal force MKR - MKS Plus Results over 10 cycles Material: Cu. Sn Withdrawal force 14 Plating: Sn 12 F [N] 10 8 6 4 2 0 1 2 3 4 5 6 7 8 9 10 Cycle Maximum Average Minimum 24 August 2005 27

5. 9 Crimp measurements MKR Plus Part number Nominal CSA 26780 0. 75 sqmm

5. 9 Crimp measurements MKR Plus Part number Nominal CSA 26780 0. 75 sqmm 1. 00 sqmm 1. 50 sqmm Crimp sizes Wire crimp mm Height : 1. 20 Width : 2. 25 Height : 1. 25 Width : 2. 25 Height : 1. 35 Width : 2. 25 Example - wire crimp Crimp sizes Insulation crimp mm +- 0. 05 +- 0. 10 3. 60 3. 50 3. 70 3. 60 Example - Insulation crimp ( sealed ) Seal H H Insulation claw B Copper cable B Cable insulation 24 August 2005 28

5. 9 Crimp measurements MKS Plus Part number 25701 Nominal CSA 0. 75 sqmm

5. 9 Crimp measurements MKS Plus Part number 25701 Nominal CSA 0. 75 sqmm 1. 00 sqmm 1. 50 sqmm Crimp sizes Wire crimp mm Height : 1. 20 Width : 2. 25 Height : 1. 25 Width : 2. 25 Height : 1. 35 Width : 2. 25 Example - wire crimp Crimp sizes Insulation crimp mm +- 0. 05 +- 0. 10 3. 60 3. 50 3. 70 3. 60 Example - Insulation crimp ( sealed ) Seal H H Insulation claw B Copper cable B Cable insulation 24 August 2005 29

5. 10 Crimp tensile strength Fmin Only wire crimp, without insulation crimp Nominal CSA

5. 10 Crimp tensile strength Fmin Only wire crimp, without insulation crimp Nominal CSA Cable construction ( FLR ) Force 0. 75 sqmm 19 strand x Ø 0. 22 mm Fmin > 80 N 1. 00 sqmm 19 strand x Ø 0. 24 mm Fmin > 100 N 1. 50 sqmm 19 strand x Ø 0. 30 mm Fmin > 140 N * Measured by Lear T&C 24 August 2005 30

5. 11 Vibration requirements, Tests with connected housings, For full description see DIN 72585

5. 11 Vibration requirements, Tests with connected housings, For full description see DIN 72585 -2, March 1996 Test group C Visual check R Contact resistance 7 Vibration requirements with free-standing connected terminals, gradient K 2: 30 g, 3 -way axis for 50 h at ambient and 120°C, supported at 100 mm contact disconnection: t<1 s, R<7 Contact resistance 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 Visual check 24 August 2005 31

5. 12 Contact disconnection During the total vibration test time of 300 hours, the

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 32

5. 13 Climate tests with connected housings For full description see DIN 72585 -2,

5. 13 Climate tests with connected housings For full description see DIN 72585 -2, March 1996 Test group K Visual check R Contact resistance Insulation resistance Humidity change 21 days humidity change to DIN 50016 FW 24: 23°C/40°C, 83% / 92% rel. H, 1 cycle=24 h R Contact resistance Insulation resistance Temperature change 50 cycles, gradient K 2, - 40°C / +140°C Contact resistance, Insulation resistance, Visual check 24 August 2005 33

5. 14 Water sealing ( IP 9 K ), Tests with connected housings For

5. 14 Water sealing ( IP 9 K ), Tests with connected housings For full description see DIN 72585 -2, March 1996 Test group L Visual check Insulation resistance Water sealing IP 9 K DIN 40050 Part 9, high pressure jet wash Insulation resistance Jet wash and spray distribution for test equipment to certify protection against high pressure water ingress Water gradient 9 K Visual check 24 August 2005 34

5. 15 Thermal testing Temperature / Running time MKR - MKS Plus 1. 00

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 ) Plating: Sn Temperature [°C] Material: Cu. Sn Time [sec] 24 August 2005 35

5. 15 Thermal testing Temperature / Running time MKR - MKS Plus 2. 50

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 ) Plating: Sn Temperature [°C] Material: Cu. Sn Time [sec] 24 August 2005 36

120 23 / +-5 23 Temperature [° C ] 5. 16 Dynamic testing 0

120 23 / +-5 23 Temperature [° C ] 5. 16 Dynamic testing 0 50 100 Time [ h ] There should be no interuption of the current flow during the test 24 August 2005 37

6. Environmental simulation Protection against dust penetration: In accordance with DIN 72585 -2 and

6. Environmental simulation Protection against dust penetration: In accordance with DIN 72585 -2 and DIN 40050 -9, a dust mist was created from 50% limestone and 50% pulverised ash. Approximately 2 kg 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 72585 -2 and EN ISO 6988, three cycles of 72 h 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 72585 -2 and DIN 50021 -SS, the test was carried out over 90 h with a concentrated test solution spray of 50 +/-5 g sodium chloride. Conclusion : Protection against salt spray was in accordance with the specification. 24 August 2005 38

7. Chemical resistance For this test, the samples were sprayed for 5 s with

7. Chemical resistance For this test, the samples were sprayed for 5 s with each of the chemicals listed below and then connected for 24 h at 80°C. • Diesel fuel to DIN EN 590 • Fuel mixture (70% Diesel and 30% FAM test liquid to DIN 51604 -B and DIN 51604 -2) • Motor oil, SAE 30 to DIN 51511 • Brake fluid to DIN ISO 4925 • Antifreeze • Transmission oil, SAE 80 W-90 to DIN 51512 Conclusion: Protection against these chemicals was in accordance with the specification 24 August 2005 39

8. Documentation summary Lear T&C - specifications: • GHW-WN 98011 110 Construction rules for

8. Documentation summary Lear T&C - specifications: • GHW-WN 98011 110 Construction rules for open, uninsulated crimped terminals • GHW-WN 95215 001 Test rules for crimped connectors, general requirements and processing rules Special specifications: • DIN 72585 -2 K 2 Version 1996 • DIN IEC 60512 -3 Version 2002 • DIN EN ISO 8092 -2 Version 1998 • DIN 40050 -9 Version 1993 • Applicable regulations, typically standards 24 August 2005 40

9. Benefits MKR Plus / MKS Plus is a proven design with over four

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 41