REMA DIN 80, DIN 160, DIN 320 Technical Information

REMA Lipprandt GmbH & Co. KG

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REMA – TECHNICAL INFORMATION

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DIN 80, 160, 320

C O N N E C T O R D A T A S H E E T

Page 1 of 13

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REMA – TECHNICAL INFORMATION

REMA is the leading supplier of DIN-style (DIN standard 43589)
quick-disconnect power connectors. These quick disconnect power

In order to withstand the frequent use in these rough environments
it is imperative that the construction of these connectors be

brand DIN-style connectors exceed the

requirement of the DIN Standard 43589 for both mechanical and

The three traditional sizes of power connectors are based upon the

To meet the demands of newer high-current applications, including

has developed a larger capacity DIN 640 A

Housing constructed of glass fiber reinforced composite
material for extreme durability and resistance battery acid

engineered contacts made of high grade electrolyte

In compliance with machinery directive 2006/42 EG and

Accepts REMA DIN-Style Connector Options including
coding/locking pins, air supply, auxiliary contacts and

Main Contacts are made from E-Cu copper optimized for
crimp connection. Only the use of REMA crimp equipment

REMA connectors for electrically-operated trucks:

Plug and Socket optional with red or black

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DIN 80, 160 and 320

Connector datasheet

connectors are used in a variety of applications, including:

 Materials Handling
 Aerial Lift
 Sweeper / Scrubber
 Utility Vehicles
 Motive Power
 Battery Chargers

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extremely robust. The REMA

electrical durability.

amperage requirements: DIN 80 A, DIN 160 A, DIN 320 A

“fast charging”, REMA®
connector.

Features of the REMA® DIN-style connector include:



 REMA

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



therefore with „CE“ Marking



handles

 Small number of parts

 Easy, intuitive assembly



results in full warranty.

 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



removable handles

Page 2 of 13

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REMA – TECHNICAL INFORMATION

DIN 43589-1

DIN 80

DIN 43589-1

DIN 160

DIN 43589-1

DIN 320

Temperature Chats

Temperature rise at constant current

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Temperature rise at constant current

Temperature rise at constant current

Page 3 of 13

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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

Technical specifications

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* Attention: Current Reduction caused by smaller wire size

Page 4 of 13

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REMA – TECHNICAL INFORMATION

Assembly of REMA twin plug and socket

2. Snap locking part (5) into the contact receiving part. With

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

4. Screw strain relief (7) onto the wires by means of a cross

Caution: To avoid damaging the wire insulations, the screws

Plug

Socket

The following combinations are possible:

Insert adaptor for pilot contacts (3) into the contact

Connect pilot contacts (4) with the connecting lines

Insert adaptor for pilot contacts (3) into the contact

Connect auxiliary contacts (4a) with the supply

Assembly of REMA DIN connectors

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connectors EN 1175-1, DIN 43589 connectors

1. Insert main contacts (2) into the contact receiving part (1)

Caution: Observe polarity of connections!

that, the seat of the main contacts is fixed in the casing.

the coding pin, use the ejector tool (Item-No. 75058-01).

head screw driver.

(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!

A. Pilot contacts



receiving part (1)



and insert into the adaptor (5)

B. Pilot contacts and auxiliary contacts



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.



lines and insert into the contact receiving part (1).

Page 5 of 13

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REMA – TECHNICAL INFORMATION

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

Housing Front View and Assignment

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Page 6 of 13

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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

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

A = 8

A = 8

B = 11

B =11

C = 46

C = 71,2

D = 44

D = 63,5

E = 18

E = 20

A = 9

A = 9

B = 12,5

B = 12,5

C = 50

C = 71,2

D = 44

D = 63,5

E = 18

E = 20

E = 20

E = 20

E = 20

E = 20

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16

25

35

50

70

95

A = 11
B = 14,5
C = 71,2
D = 63,5

A = 13,1
B = 17
C = 72,3
D = 64,5

A = 11
B = 14,5
C = 72,3
D = 68,3

A = 13,1
B = 17
C = 82,5
D = 68,3

A = 15
B = 19,8
C = 103
D = 88,8
E = 25

*All Values in mm

Page 7 of 13

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REMA – TECHNICAL INFORMATION

Pilot Contact Adapter for Socket

Pilot Contact Adapter for Plug

Pilot Bushing

Pilot Pin

Auxiliary Bushing

Auxiliary Pin

*
*

*

*

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

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Optional Auxiliary and Pilot Contacts of DIN 80, DIN 160 and DIN 320

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Dimensions of Auxiliary and Pilot Contacts of DIN 80, DIN 160 and DIN 320

* *

*Image similar

*All Values in mm

Page 8 of 13

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REMA – TECHNICAL INFORMATION

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

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Optional Handles, Screwed or Moulded of DIN 80, DIN 160 and DIN 320

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Page 9 of 13

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REMA – TECHNICAL INFORMATION

Coding

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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 10 of 13

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Connector with air coupling

Air circulation during a battery charging cycle

This technology was developed for battery-driven
submarines. Air introduced into the bottom of the
battery cell creates air bubbles that circulate and cool

REMA has developed optional adapters which can be
mounted in the connector housings thus creating a

This integral connection is favored over two
independent systems for the obvious benefits of

Airadapter for tubes with an inside ø of 6 mm + 8 mm

Airadapter for tubes with an inside ø of 6 mm + 9 mm

Material: PP, batt.-acid proof

provides several benefits including:

 Reduction in charging time
 Increased battery charging capacity
 Extended overall battery life

the electrolyte.

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„two-in-one“-connection: electrical energy and air.

handling and security.

DIN80, DIN160, DIN 320

DIN 160

Page 11 of 13

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REMA – TECHNICAL INFORMATION

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)

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

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

>125

E L E C T R I C A L

Solution ATracking Index - CTI Solution B
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)

Appendix 1.

Datasheet of Acid proof Material PP CoPo GF 30

Crealien -EP8G6HS / L * 0083 Natur

PP-Copo.30%GF

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g/10 min ISO 1133 A

MPa ISO 527-1/-2

°C DIN EN 60695-10-2

V V IEC 60112 IEC 60112

mm/min class -

DIN EN 60695-11-10 DIN EN
60695-2UL 94

>600M >600

HG/HB/--

Page 12 of 13

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REMA – TECHNICAL INFORMATION

Appendix 2.

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Datasheet of Material PA6-GF30

Purpose-build Polyamide 6 (30% GF, highly impact resistant modified)

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Page 13 of 13