REMA DIN 80 Manual

Page 1of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
DIN 80, 160, 320
C O N N E C T O R D A T A S H E E T

Page 2of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
DIN 80, 160 and 320
Connector datasheet
REMA
is the leading supplier of DIN-style (DIN standard 43589)
quick-disconnect power connectors. These quick disconnect power
connectors are used in a variety of applications, including:
Materials Handling
Aerial Lift
Sweeper / Scrubber
Utility Vehicles
Motive Power
Battery Chargers
In order to withstand the frequent use in these rough environments
it is imperative that the construction of these connectors be
extremely robust. The REMA
brand DIN-style connectors exceed the
requirement of the DIN Standard 43589 for both mechanical and
electrical durability.
The three traditional sizes of power connectors are based upon the
amperage requirements: DIN 80 A, DIN 160 A, DIN 320 A
To meet the demands of newer high-current applications, including
“fast charging”, REMA®
has developed a larger capacity DIN 640 A
connector.
Features of the REMA® DIN-style connector include:

Housing constructed of glass fiber reinforced composite
material for extreme durability and resistance battery acid
REMA
engineered contacts made of high grade electrolyte
copper and silver plated for corrosion protection
UL 1977 certified component
Meets or exceeds the following industry standards:
DIN 43589, EN 1175-1, IEC 20989, UL1977

In compliance with machinery directive 2006/42 EG and
therefore with „CE“ Marking

Accepts REMA DIN-Style Connector Options including
coding/locking pins, air supply, auxiliary contacts and
handles
Small number of parts
Easy, intuitive assembly

Main Contacts are made from E-Cu copper optimized for
crimp connection. Only the use of REMA crimp equipment
results in full warranty.
REMA connectors for electrically-operated trucks:
80 AMP, 160 AMP, 320 AMP
Materials: Black plastic, Grey plastic, bat.-acid-
proof Red plastic, RAL 3000 (80 AMP, 160 AMP)
with coding pins for wet- or dry batteries
with or without auxiliary contacts
with or without sub-auxiliary contacts
with cable clamp
Socket optional with moulded on handle
Plug and Socket optional with screwed or clipped
handles

Plug and Socket optional with red or black
removable handles

Page 3of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
DIN 43589-1
DIN 80
Temperature rise at constant current
DIN 43589-1
DIN 160
Temperature rise at constant current
DIN 43589-1
DIN 320
Temperature rise at constant current
Temperature Chats

Page 4of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
DIN 80
DIN 160
DIN 320
Electrical
Rating current (Amperes) according
wire size
16mm² - 80A
25mm² - 80A
35mm² - 80A
16mm² - *
25mm² - *
35mm² - 160A
50mm² - 160A
50mm² - *
70mm² - 320A
95mm² - 320A
Rating voltage (Volts)
150 V
150 V
150 V
Dielectric Withstanding Voltage (AC)
2000 VAC
2000 VAC
2000 VAC
Operating Temperature ℃/ °F
- 20 °C to + 105 °C
- 13 °F to + 221 °F
- 20 °C to + 105 °C
- 13 °F to + 221 °F
- 20 °C to + 105 °C
- 13 °F to + 221 °F
Mechanical
Degree of protection
IP23
IP23
IP23
Life cycles ( No Load)
5000
5000
5000
Disconnect at Overload
Voltage
Current
inductively
5 mating cycles
96 V
200 A
0,5 mH
5 mating cycles
96 V
400 A
0,5 mH
5 mating cycles
96 V
800 A
0,5 mH
Average Mating / Unmating Force
Mating: 78 N
Unmating: 58 N
Mating: 80 N
Unmating: 61 N
Mating: 88 N
Unmating: 76 N
Advise torque of the fixing screws
2,5 Nm
3,5 Nm
3,5 Nm
Material
Housing
Acid proof PP CoPo GF 30
PA6-GF30
Acid proof PP CoPo GF 30
PA6-GF30
Acid proof PP CoPo GF 30
PA6-GF30
Main Contacts
Cu-ETP DIN EN 13601 CW004A
Surface: AG 6µm
Cu-ETP DIN EN 13601 CW004A
Surface: AG 6µm
Cu-ETP DIN EN 13601 CW004A
Surface: AG 6µm
Pilot and Auxiliary Contacts
CuZn40 Pb2
Surface: AG 6µm
CuZn40 Pb2
Surface: AG 6µm
CuZn40 Pb2
Surface: AG 6µm
Specifications
Specifications
EN 1175-1
DIN 43589
UL 1977
In compliance with machinery directive 2006/42 EG and therefore with “CE” Marking
* Attention: Current Reduction caused by smaller wire size
Technical specifications

Page 5of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Assembly of REMA twin plug and socket
connectors EN 1175-1, DIN 43589 connectors
1. Insert main contacts (2) into the contact receiving part (1)
Caution: Observe polarity of connections!
2. Snap locking part (5) into the contact receiving part. With
that, the seat of the main contacts is fixed in the casing.
3. Insert coding pin into the casing from the front. It must now
be possible to read the desired operating voltage in the
inspection window of the locking part. To facilitate removal of
the coding pin, use the ejector tool (Item-No. 75058-01).
4. Screw strain relief (7) onto the wires by means of a cross
head screw driver.
Caution: To avoid damaging the wire insulations, the screws
(7) must only be slightly tightened!
Connecting the wires:
Remove insulation from the wire ends by means of a wire
stripper or wire stripping knife. Ensure that any paper or
plastic residue from possible intermediate layers is removed.
The following stripping lengths must be observed:
Crimp wire ends and contacts with REMA pressing tools (refer
to REMA tool catalogue).
Caution:
The crimp inserts must be selected in accordance with the
wire diameter. Improper pressing may lead to the plug-in
device overheating. Apart from the possible destruction of the
casing, this may lead to injuries!
Plug
Socket
The following combinations are possible:
A. Pilot contacts

Insert adaptor for pilot contacts (3) into the contact
receiving part (1)

Connect pilot contacts (4) with the connecting lines
and insert into the adaptor (5)
B. Pilot contacts and auxiliary contacts

Insert adaptor for pilot contacts (3) into the contact
receiving part(1)
Connect pilot contacts (4) with the connecting lines
and insert into the adaptor (5)
Connect auxiliary contacts (4a) with the supply
lines and insert into the contact receiving part (1).
C. Air transport system
Insert the adaptor for the air transport system (3a)
into the contact receiving part.
D. Air transport system and auxiliary contacts
Insert the adaptor for the air transport system (3a)
into the contact receiving part.

Connect auxiliary contacts (4a) with the supply
lines and insert into the contact receiving part (1).
Assembly of REMA DIN connectors

Page 6of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Housing Front View and Assignment
Connectors Plug Dimension
DIN 80, 160, 320
Connectors Socket Dimension
DIN 80, 160, 320
Dimensions Housing DIN 80, DIN 160 and DIN 320
Main Power Contact
Auxiliary Contacts
Main Power Contact
Pilot Contacts or Air Coupling

Page 7of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Dimensions of Contact Pin and Contact Bushing of DIN 80, DIN 160 and DIN 320
Main Contact PIN
Main Contact Bushing
Main Contact Dimensions
Cross section / sqmm
DIN 80
DIN 160
DIN 320
16
A = 6,1
A = 6,1
B = 8,4
B = 8,4
C = 46
C = 71,2
D = 44
D = 63,5
E = 18
E = 20
25
A = 8
A = 8
B = 11
B =11
C = 46
C = 71,2
D = 44
D = 63,5
E = 18
E = 20
35
A = 9
A = 9
B = 12,5
B = 12,5
C = 50
C = 71,2
D = 44
D = 63,5
E = 18
E = 20
50
A = 11
B = 14,5
C = 71,2
D = 63,5
E = 20
A = 11
B = 14,5
C = 72,3
D = 68,3
E = 20
70
A = 13,1
B = 17
C = 72,3
D = 64,5
E = 20
A = 13,1
B = 17
C = 82,5
D = 68,3
E = 20
95
A = 15
B = 19,8
C = 103
D = 88,8
E = 25
*All Values in mm

Page 8of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Optional Auxiliary and Pilot Contacts of DIN 80, DIN 160 and DIN 320
Pilot Contact Adapter for Socket
Pilot Contact Adapter for Plug
Pilot Bushing
Pilot Pin
Auxiliary Bushing
Auxiliary Pin
*
*
*
*
Dimensions of Auxiliary and Pilot Contacts of DIN 80, DIN 160 and DIN 320
**
*Image similar
Pilot and Auxiliary Contact Dimensions
Pilot or Auxiliary
DIN 80
DIN 160
DIN 320
Auxiliary Contacts
A = 2,4
A = 2,4
A = 2,4
B = 4
B = 4
B = 3,9
C = 36
C = 36
C = 37
D = 40
D = 36
D = 64
E = 8
E = 8
E = 7,6
Pilot Contact
A = 2,45
A = 2,45
A = 2,45
B = 3,9
B = 3,9
B = 3,9
C = 31
C = 31
C = 31
D = 35
D = 35
D = 35
E = 7,5
E = 7,5
E = 7,5
*All Values in mm

Page 9of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Optional Handles, Screwed or Moulded of DIN 80, DIN 160 and DIN 320
Handles: Screwed or Moulded
Screwed Version for Socket and Plug
Moulded Version for Sockets only
Screwed Handle
DIN 80
DIN 160 -
320
Moulded Handle
DIN 80
DIN 160

Page 10 of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Coding
Currently two types of batteries are used in the market: Wet batteries | Dry or gel batteries. Both types work only with chargers which
have a particular specification corresponding to the two different types of batteries. A mismatch between battery and charger (e. g. a
wet battery to a dry charger or vice versa) can result in the destruction of the battery.
To help prevent a mismatch REMA® has developed a special coding system where only matching batteries and chargers can be
connected. Nevertheless the usage of the wet/dry coding pin allows the connection between the electric motor and both types of
batteries. For the motors, no difference between the wet and dry batteries exists.
This system can be set for six different voltages ranging from 24V - 96V. The hexagonal coding pin shows these different voltages on
each side. When assembling the plugs and sockets the correct voltage is chosen by turning the coding pin, so that the required voltage
number appears in a window of the housing. With the help of this registered design, licensed to the other German plug manufacturers,
the plugs and sockets from REMA® are particularly suitable for the requirements of daily use.

Page 11 of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Connector with air coupling
Air circulation during a battery charging cycle
provides several benefits including:
Reduction in charging time
Increased battery charging capacity
Extended overall battery life
This technology was developed for battery-driven
submarines. Air introduced into the bottom of the
battery cell creates air bubbles that circulate and cool
the electrolyte.
REMA has developed optional adapters which can be
mounted in the connector housings thus creating a
„two-in-one“-connection: electrical energy and air.
This integral connection is favored over two
independent systems for the obvious benefits of
handling and security.
DIN80, DIN160, DIN 320
Airadapter for tubes with an inside ø of 6 mm + 8 mm
DIN 160
Airadapter for tubes with an inside ø of 6 mm + 9 mm
Material: PP, batt.-acid proof

Page 12 of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Crealien -EP8G6HS / L * 0083 Natur
PP-Copo.30%GF
Properties
Unit
Standard
Values
P H Y S I C A L
Density
g/cm³
ISO 1183
1,12
Mould Shrinkage (Plate 61*61*2) [ md/pmd ]
%
ISO 294-4
0,2/0,4
(24 h) Water Absorption
%
ISO 62
0,02
(to saturation) Water Absorption
%
ISO 62
0,10
Melt Flow Rate (MFR)
g/10 min ISO 1133 A
5
M E C H A N I C A L
Izod-Impact Strength notched +23°C / -30°C
kJ/m²
ISO 180/A
16
Charpy-Impact Strength notched +23°C / -30°C
kJ/m²
ISO 179-1/1eA
Charpy-Impact Strength +23°C / -30°C
kJ/m²
ISO 179-1/1eU
Tensile Yield Strength
MPa
ISO 527-1/-2
80
Elongation at Break
%
ISO 527-1/-2
4
Flexural Strength
MPa
ISO 178
100
Flexural Modulus +23°C
MPa
ISO 178
Tensile Modulus
MPa ISO 527-1/-2
6600
T H E R M A L
1,81 MPa Heat Distortion Temperature (HDT)
°C
ISO 75-1/-2
148
0,45 MPa
°C
ISO 75-1/-2
161
50°C/h 49 NVICAT Softening Temperature
°C
ISO 306
132
50°C/h 9,8 N
°C
ISO 306
163
Ball Identation test
°C DIN EN 60695-10-2
>125
E L E C T R I C A L
Solution ATracking Index - CTI Solution B
V V IEC 60112 IEC 60112 >600M >600
F L A M M A B I L I T Y
Burning rate (2mm/750/850/960 °C) Glow wire test 2mm
(3,2/1,6/0,8mm) UL94 (3,2mm)
mm/min class - DIN EN 60695-11-10 DIN EN
60695-2UL 94 HG/HB/--
Stand: 15.12.2011
Änderungen vorbehalten I Subject to change reserved
Appendix 1.
Datasheet of Acid proof Material PP CoPo GF 30

Page 13 of 13
REMA Lipprandt GmbH & Co. KG
Spichernstraße 11
53175 Bonn
Tel.: [phone]
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-bonn.de
REMA Technology Shanghai Co. Ltd
No. 1590 Songfu Road
Qingpu Industry Zone
201706 Shanghai
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-shanghai.com
REMA USA, LLC
101 Park Place Court
Greenville, SC 29607
Tel.: [phone];
Fax: [phone]
E-Mail: [e-mail]
Web: www.rema-ev.com
REMA –TECHNICAL INFORMATION
Appendix 2.
Datasheet of Material PA6-GF30
Purpose-build Polyamide 6 (30% GF, highly impact resistant modified)