CEENorm 21012-TLS, 21013-TLS, 31000-TLS, 21017-TLS, 21001-TLS Installation Instructions

Installation manual plugs and connectors with screw connection

(16/32 A)

Issue 04.2016
2016-04-01

EN

60003213

Installation manual plugs and connectors with screw connection (16/32

Table of contents

1 About this manual 3

1.1

Structure of the warnings 3

1.2

Symbols used 4

1.3

Signal words used 4

Intended use 5

2

General safety instructions 6

3

Packaging, transport and storage 7

4

4.1

Packaging 7

4.2

Transport 7

4.3

Storage 7

Design 8

5

Assembly and disassembly 9

6

6.1

Connecting a cable to a 16-A / 32-A plug or socket 9

6.2

Disconnecting a cable from a 16-A / 32-A plug or socket 11

Cleaning and care 14

7

A)

Decommissioning and disposal 15

8

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About this manual

1

This manual
– describes the assembly and disassembly of plugs and sockets with screw connections of Bals El-

ektrotechnik GmbH & Co. KG
– is an integral part of the product and must be kept in safe custody during the product service life
– must be read carefully and understood before use and any work.

Structure of the warnings

1.1

The following picture illustrates the structure of a sample warning.

1 Hazard-specific symbol
2 Signal word
3 Type and source of the hazard
4 Possi ble consequences of failing to comply
5 Procedure for avoiding hazards

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Installation manual plugs and connectors with screw connection (16/32

Symbols used

1.2

General warning of a hazardous area

Warning – dangerously high voltage

Notice

Signal words used

1.3

All warnings in this manual are clearly highlighted. The following signal words are used for warnings:

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DANGER Warns of dangers which will lead to serious injuries or to death if the instructions are not fol-

lowed.

WARNING Warns of dangers that may lead to serious injuries or to death and/or cause considerable dam-

age to property if the instructions are not followed.

CAUTION Warns of dangers that may lead to reversible injuries and/or considerable damage to property if

the instructions are not followed.

NOTICE Warns of dangers that may lead to operational disruptions and/or considerable damage to prop-

erty. Damage to the environment, too, may occur if the instructions are not followed.

Installation manual plugs and connectors with screw connection (16/32
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Intended use

2

Plugs and sockets with screw connections are built for professional use. The installation and the fixed
connection to the mains supply should be carried out only by trained and qualified experts.

Any use going beyond the intended use is considered to be improper. The manufacturer is not liable
for damages resulting from improper use. Any such risk shall be borne solely by the user.

In case of unauthorised modifications or conversions, the CE conformity becomes null and void, and
thus, also all claims for warranty. Modifications may lead to risks for life and limb as well as damage
to the plugs and sockets or loads connected.

Factory-fitted labels and markings on the plugs and sockets should not be removed, modified or
blurred.

Protect against foreign bodies and impact of weather
The plugs and sockets meet either the protection degree IP44, IP54 or IP67 in accordance with DIN

EN 60529 (VDE 0470-1), depending on the respective design. Each of these mean:

– Protection degree IP44:

– Protected against solid bodies with a diameter beyond 1.0 mm, e.g. a wire

– Protection against water sprayed from all sides
– Protection degree IP54:

– Protected against dust in damaging quantity

– Complete protection against contact

– Protection against water sprayed from all sides
– Protection degree IP67:

– Dust-proof

– Complete protection against contact

– Protection against temporary immersion

Environment

The following operating temperatures apply for the safe operation of the product:

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Standard version

-25 °C ... +40 °C -33 °C ... +49 °C

General safety instructions

3

– Safe use is ensured only if this manual is followed completely.
– Before installation, commissioning or operation, read this manual thoroughly.
– The plugs and sockets must be installed, maintained and put into operation properly by qualified

experts in accordance with the laws, ordinances and standards.
– Keep easily combustible and explosive materials away from the plugs and sockets.
– Handle the cables with care

– by always pulling at the plug and not the cable when unplugging,

– by preventing the cable from getting damaged mechanically,

– by keeping intense heat away.
– Never use faulty products or products with dirty, scratched or damage contacts.
– Keep the contacts on the product clean.
– Avoid tripping hazards.

Military version

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Packaging, transport and storage

4

Packaging

4.1

Packaging materials are valuable raw materials and can be reused. The packaging materials should
therefore be brought to an appropriate recycling facility. If this is not possible, dispose of the packag­ing materials according to the locally applicable regulations.

Transport

4.2

Check the delivery for completeness and integrity. If you identify transit damage or if the delivery is in­complete, notify your dealer or supplier immediately.

Storage

4.3

The product must be stored in clean condition and protected from dust and humidity. The original
packaging is best suited for this purpose.

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Installation manual plugs and connectors with screw connection (16/32

Design

5

Based on an example, the following figure illustrates the main components of the plugs and sockets
with screw connections.

1 Use with screw terminals for all types of copper conductors
2 Housing
3 Cable gland with multi-grip as integrated strain relief

Conductor cross-sections

The following table displays the possible conductor cross-sections that can be connected to the plugs
and sockets:

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Design Possible conductor cross-section

16 A 1 mm
32 A 2.5 mm2 ... 6 mm

2

... 2.5 mm

2

2

Cable diameter

The following table displays the cable diameters that can be used for plugs and sockets with mul­ti-grip:

Design Possible cable diameter

16 A, 3-pin to 5-pin 8 mm ... 18 mm
32 A, 3-pin to 5-pin 11 mm ... 23 mm

Technical specifications

The technical specifications of the plugs and sockets depend on the design. You will find them in our
catalogue or on our website http://www.bals.com.

Installation manual plugs and connectors with screw connection (16/32
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Assembly and disassembly

6

DANGER

Danger to life by electrical voltage

The supply cable may carry high electrical voltage that is fatal. Pay attention to the five safety rules of
electricity:

1. De-energise

2. Secure the supply from being switched on again

3. Ensure the de-energised condition

4. Connect to earth and short circuit

5. Cover or cordon off adjacent live parts

Connecting a cable to a 16-A / 32-A plug or socket

6.1

Proceed as follows:

1. Make sure that the cable is de-energised.

2. Loosen the screws in order to disconnect the inserts with the screw terminals (1) from the
housing (2).

3. Remove the insert with the screw terminal in front out of the housing.

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4. Push the cable about 50 cm wide through the cable gland and housing.

5. Strip the cable to the required length (16-A designs: 60 mm; 32-A designs: 70 mm).

6. Remove the insulation from the individual conductors (16-A designs: 7 mm; 32-A designs:
12 mm).

7. For better, permanent contact, provide the individual conductors with suitable conductor end
sleeves.

8. The terminals are open at the time of delivery. Guide the individual conductors into the open­ing (5) and tighten the screws (4) with a torque of at least 0.8 Nm. Take care to see that only
the individual conductor (without insulation) is clamped. Pay attention to the marking of the
terminals and ensure that the assignment of the individual conductors to the terminals is cor­rect.

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9. Connect the housing and the insert with the screws foreseen for this purpose.

10. Next, tighten the cable gland (3). The tightening torque must be between 4 Nm and 7 Nm for
the 16-A designs and between 5 Nm and 9 Nm for the 32-A designs. Please refer to the em­bossing on the cable gland for the exact value of the respective design. Secure the cable gland
using the screw placed on the side for this purpose (6, depending on the design).

11. Check that the cable is seated tightly in the plug or socket.

Disconnecting a cable from a 16-A / 32-A plug or socket

6.2

1. Make sure that the cable is de-energised.

2. If the cable gland (3) is secured with the help of a screw (6), loosen this screw.

3. Loosen the cable gland.

4. Disconnect the joint between the housing (2) and the insert (1). To do this, loosen the con­necting screws.

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Installation manual plugs and connectors with screw connection (16/32

5. Push the housing and the cable gland back on the cable until the connections in the front part
are easily accessible.

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6. Loosen the screws (4) of the terminals and pull out the individual conductor.

Installation manual plugs and connectors with screw connection (16/32
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7. Pull the cable out of the housing and out of the cable gland.

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Cleaning and care

7

It is recommended to clean the device as required. Use a dry cloth to clean the device. Use a wet cloth
if the device is very dirty.

DANGER

Electrical voltage

The device contains parts that carry hazardous voltage that may be fatal.

1. Pull out the plugs to the loads before cleaning them.

2. Make sure that the plug covers are closed.

3. Never use steam or water jet cleaners.

NOTICE

Damage to the plastic parts.

Corrosive cleaning agents may attack or destroy the plastic parts.
Use only a cloth moistened with water for cleaning.

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Notes

Decommissioning and disposal

8

Send the worn-out product for recycling or for proper disposal. Always make sure to observe and fol­low the local regulations.

The product should not be disposed of in household waste. Environmental damage and risk to person­al health are avoided with proper disposal.

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Bals Elektrotechnik GmbH & Co. KG
Burgweg 22
57399 Kirchhundem
GERMANY
Tel.: +49 27 23 / 7 71-0
Fax: +49 27 23 / 7 71-1 77
E-mail: [e-mail]

Disclosure to third parties only with the consent of
Bals Elektrotechnik GmbH & Co. KG. All rights reserved.
Only valid at the time of printing. Update when reused.