AS/NZS 61535.1:2003

1 - AS/NZS 61535.1:2003 INSTALLATION COUPLERS - GENERAL REQUIREMENTS
4 - PREFACE
5 - CONTENTS
6 - 1 SCOPE
7 - 2 REFERENCED DOCUMENTS
7 - 3 DEFINITIONS
8 - 3.1 Caps
8 - 3.2 Connecting capacity
8 - 3.3 Distribution block of an installation coupler
8 - 3.4 Installation coupler
8 - 3.5 Installation plug
8 - 3.6 Installation socket
8 - 3.7 Nominal voltage of a system
8 - 3.8 Non-rewireable installation coupler
8 - 3.9 Non-rewireable moulded-on installation coupler
8 - 3.10 Non-rewireable non-moulded-on installation coupler
8 - 3.11 Permanent connection
8 - 3.12 Rated current
9 - 3.13 Rated voltage
9 - 3.14 Readily accessible
9 - 3.15 Retaining means
9 - 3.16 Rewireable installation coupler
9 - 3.17 Routine test
9 - 3.18 Type test
9 - 4 GENERAL REQUIREMENTS
9 - 4.1 General
9 - 4.2 Instructions
9 - 5 GENERAL TEST REQUIREMENTS
9 - 5.1 General
9 - 5.2 Samples
9 - 5.3 Cables on non-rewireable samples
10 - 5.4 Order of tests
10 - 5.5 Number of samples
10 - 5.6 Failure of a sample
10 - 5.7 Routine testing
10 - 6 RATINGS
10 - 6.1 Voltage rating
10 - 6.2 Current rating
11 - 6.3 Compliance
11 - 6.4 Rated connecting capacity
11 - 7 CLASSIFICATION
11 - 8 MARKINGS
11 - 8.1 General information
12 - 8.2 Symbols
12 - 8.3 Visibility of markings
12 - 8.4 Marking of terminals
13 - 8.5 Test of markings
13 - 8.6 Information on suitable cable types
13 - 8.7 Use of caps
13 - 8.8 Information on PE-conductor
13 - 8.9 Cabling information
13 - 8.10 Availability of manufacturer™s instructions
13 - 8.11 Warning on dangerous compatibility
13 - 9 DIMENSIONS AND COMPATIBILITY
13 - 9.1 Improper connection
14 - 9.2 Compatibility within installation coupler systems
14 - 9.3 Compatibility with systems that comply with other Standards
15 - 10 PROTECTION AGAINST ELECTRIC SHOCK
15 - 10.1 IP rating
15 - 10.2 Access to live parts
15 - 10.3 External parts
15 - 11 TERMINALS AND TERMINATIONS
15 - 11.1 Connection of conductors
16 - 11.2 Terminals
16 - 11.2.1 Terminals for rewireable couplers
16 - 11.2.2 Terminals for non-rewireable couplers
16 - 11.3 Cable sizes
16 - 11.3.1 Cable sizes for rewireable couplers
17 - 11.3.2 Cable sizes for non-rewireable couplers
17 - 11.4 Restrictions on the method of clamping conductors
17 - 12 CONSTRUCTION
17 - 12.1 Earth connection
17 - 12.2 Twisting or rotation of contacts
18 - 12.3 Fixing of contacts
18 - 12.4 Isolation of parts
18 - 12.4.1 Isolation of conductors
18 - 12.4.2 Isolation of terminals
18 - 12.5 Fixing of housing
18 - 12.6 Continuity of earth contact
19 - 12.7 Design of terminals
19 - 12.7.1 Loose conductor strands
19 - 12.7.2 Test for rewireable installation couplers
19 - 12.7.3 Test for non-rewireable non-moulded-on installation couplers
20 - 12.7.4 Inspection of non-rewireable moulded-on installation couplers
20 - 12.8 Prohibited items
20 - 12.9 Retaining means
20 - 12.10 Distribution blocks
20 - 12.11 Installation plug shroud
20 - 12.12 Wiring of non-rewireable installation couplers
20 - 12.13 Space for earthing conductor
21 - 12.14 Separation of cable in non-rewireable installation couplers
21 - 13 PROTECTION AGAINST SOLID FOREIGN OBJECTS AND INGRESS OF WATER
21 - 13.1 Protection against foreign solid objects
21 - 13.2 Resistance to harmful ingress of water
21 - 14 INSULATION RESISTANCE AND ELECTRIC STRENGTH
21 - 14.1 General
21 - 14.2 Resistance to humidity
22 - 14.3 Insulation resistance test
22 - 14.4 Electric strength test
23 - 15 CONSTRUCTION OF CONTACTS
23 - 15.1 Socket-contact pressure
23 - 15.2 Resistance of connections
23 - 15.3 Resilience of contacts
23 - 16 TEMPERATURE RISE
24 - 17 NORMAL AND ABNORMAL OPERATION
24 - 18 FORCES NECESSARY TO ENGAGE AND DISENGAGE THE PARTS OF THE INSTALLATION COUPLER
25 - 19 CABLES AND THEIR CONNECTION
25 - 19.1 Selection and size
25 - 19.2 Cable clamping
25 - 19.3 Strain relief in rewireable installation couplers
25 - 19.4 Tests for cable clamping and strain relief
27 - 19.5 Sharp edges
27 - 20 MECHANICAL STRENGTH
27 - 20.1 General
28 - 20.2 Tumbling barrel test
29 - 20.3 Mechanical strength test of the shroud
30 - 21 RESISTANCE TO HEAT AND AGEING
30 - 21.1 General
30 - 21.2 Heat test
30 - 21.3 Ball pressure test
31 - 21.4 Resistance to ageing
31 - 21.4.1 General
31 - 21.4.2 Ageing conditioning for elastomers
31 - 21.4.3 Ageing conditioning for thermoplastics
31 - 21.4.4 Ageing test criteria
31 - 21.5 Cyclic ageing
31 - 21.5.1 General
31 - 21.5.2 Cyclic ageing test
32 - 22 SCREWS, CURRENT-CARRYING PARTS AND CONNECTIONS
32 - 22.1 Screws and nuts
32 - 22.2 Alignment of screws
32 - 22.3 Contact pressure
33 - 22.4 Locking of screws and rivets
33 - 22.5 Current-carrying parts
33 - 23 CLEARANCES, CREEPAGE DISTANCE AND DISTANCES THROUGH INSULATION
35 - 24 RESISTANCE TO ABNORMAL HEAT AND TO TRACKING
35 - 24.1 Resistance to heat and fire
37 - 24.2 Resistance to tracking
37 - 25 RESISTANCE TO RUSTING
38 - APPENDIX A - GUIDE TO USE OF INSTALLATION COUPLER SYSTEMS
38 - A1 GENERAL
38 - A2 APPLICATIONS
38 - A3 INSTALLATION
40 - APPENDIX B - ROUTINE TESTING
40 - B1 GENERAL
40 - B2 EARTH (PE) CONTINUITY
41 - APPENDIX C - MANUFACTURER'S INSTALLATION INSTRUCTIONS
41 - C1 FOR REWIREABLE INSTALLATION COUPLERS
41 - C2 STRAIN RELIEF
41 - C3 NON-REWIREABLE INSTALLATION COUPLERS
41 - C4 DISTRIBUTION BLOCKS
41 - C5 INSTALLATION
43 - APPENDIX D - TEST CIRCUITS FOR TEMPERATURE RISE TESTS (See Clause 16)

This Standard applies to installation couplers with two- to five- poles with or without earthing contact and with a rated voltage up to and including 500 V a.c. and a rated current up to and including 32 A for permanent connection in indoor installation systems according to AS/NZS 3000. NOTE: Installation couplers according to this Standard are used in prefabricated houses, installation cavities (such as suspended floors and ceilings) cable trays and trunking, or in commercial show rooms, mobile or fixed stands at fairs or other exhibitions. They are also used in home and office furniture especially in office screens and partition walls. Installation couplers are a system which can replace connecting and junction boxes or other connecting devices and are intended for connection and disconnection without load. Installation couplers complying with this Standard are suitable for use at rated current in ambient temperatures not normally exceeding 25°C, but occasionally reaching 35°C. This Standard does not apply to the following: (a) Appliance couplers for household and similar general purposes within the scope of AS/NZS 3109.1. (b) Plugs and socket outlets within the scope of AS/NZS 3112.(c) Cord extension sockets within the scope of AS/NZS 3120.(d) Socket-outlet adaptors within the scope of AS/NZS 3122. (e) Plugs, socket-outlets and couplers for general industrial applications within the scope of AS/NZS 3123. NOTES: 1 This Standard may be used as a guide for installation couplers that fall outside of the scope of the Standard (e.g. for six-pole installation couplers, seven-pole installation couplers and installation couplers having a rated current greater than 32 A). 2 Installation couplers with additional contacts for voltages other than supply voltages are outside of the scope of this Standard, but the Standard may be used for the accessories involved, where applicable. 3 Guidance for the use of installation couplers is given in Appendix A. 4 Installation couplers are not intended to replace socket-outlet systems.

First published as AS 3131-1990.Jointly revised and designated as AS/NZS 3131:1995.Jointly revised and redesignated in part as AS/NZS 61535.1(Int):2001.Jointly revised and designated as AS/NZS 61535.1:2003. First published as AS 3131-1990. Jointly revised and designated as AS/NZS 3131:1995. Jointly revised and redesignated in part as AS/NZS 61535.1(Int):2001. Jointly revised and designated as AS/NZS 61535.1:2003.