KSB AS5 User manual

Alarm Switchgear with Contactor
AS5
Alarm Switchgear
Installation/Operating Manual

Legal information/Copyright
Installation/Operating Manual AS5
Original operating manual
All rights reserved. The contents provided herein must neither be distributed, copied, reproduced,
edited or processed for any other purpose, nor otherwise transmitted, published or made available to a
third party without the manufacturer's express written consent.
Subject to technical modification without prior notice.
© KSB SE & Co. KGaA, Frankenthal 03/04/2020

Contents
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Contents
1 General.................................................................................................................................................... 5
1.1 Principles ...........................................................................................................................................................5
1.2 Target group.....................................................................................................................................................5
1.3 Other applicable documents............................................................................................................................5
1.4 Symbols .............................................................................................................................................................5
1.5 Key to safety symbols/markings.......................................................................................................................6
2 Safety...................................................................................................................................................... 7
2.1 General..............................................................................................................................................................7
2.2 Intended use .....................................................................................................................................................7
2.3 Personnel qualification and personnel training.............................................................................................7
2.4 Consequences and risks caused by non-compliance with this manual .........................................................7
2.5 Safety awareness ..............................................................................................................................................8
3 Transport/Storage/Disposal .................................................................................................................. 9
3.1 Checking the condition upon delivery............................................................................................................9
3.2 Transport...........................................................................................................................................................9
3.3 Storage..............................................................................................................................................................9
3.4 Disposal ...........................................................................................................................................................10
4 Description............................................................................................................................................ 11
4.1 General description ........................................................................................................................................11
4.2 Product information as per Regulation No. 1907/2006(REACH).................................................................11
4.3 Designation.....................................................................................................................................................11
4.4 Name plate......................................................................................................................................................11
4.5 Design details..................................................................................................................................................12
4.6 Technical data.................................................................................................................................................12
4.7 Configuration and function...........................................................................................................................13
4.8 Dimensions and weights ................................................................................................................................13
4.9 Accessories ......................................................................................................................................................13
5 Installation at Site................................................................................................................................ 14
5.1 Safety regulations...........................................................................................................................................14
5.2 Checks to be carried out prior to installation...............................................................................................14
5.3 Mounting the alarm switchgear....................................................................................................................15
5.4 Electrical connection ......................................................................................................................................16
6 Commissioning/Start-up/Shutdown................................................................................................... 18
6.1 Commissioning/Start-up.................................................................................................................................18
6.1.1 Start-up...............................................................................................................................................18
6.2 Operating limits..............................................................................................................................................19
6.2.1 Ambient temperature........................................................................................................................19
6.3 Shutdown........................................................................................................................................................20
6.3.1 Shutdown ...........................................................................................................................................20
6.3.2 Measures to be taken for shutdown ................................................................................................20
7 Operation.............................................................................................................................................. 21
7.1 Control panel..................................................................................................................................................21
7.2 Acknowledging displayed faults ...................................................................................................................21
8 Servicing/Maintenance........................................................................................................................ 22
8.1 Servicing/Inspection........................................................................................................................................22
8.1.1 Maintenance schedule.......................................................................................................................22
8.1.2 Replacing the rechargeable battery .................................................................................................22
9 Trouble-shooting.................................................................................................................................. 24
10 Related Documents.............................................................................................................................. 25
10.1 Wiring diagram...............................................................................................................................................25

Contents
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10.1.1 Wiring diagram of the M1 contactor ...............................................................................................25
11 EU Declaration of Conformity............................................................................................................. 26
Index ..................................................................................................................................................... 27

1 General
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1 General
1.1 Principles
This operating manual is valid for the type series and variants indicated on the front
cover.
The operating manual describes the proper and safe use of this equipment in all
phases of operation.
The name plate indicates the type series, the main operating data and the serial
number. The serial number uniquely describes the product and is used as
identification in all further business processes.
In the event of damage, immediately contact your nearest KSB service facility to
maintain the right to claim under warranty.
1.2 Target group
This operating manual is aimed at the target group of trained and qualified specialist
technical personnel.
1.3 Other applicable documents
Table1: Overview of other applicable documents
Document Contents
Sub-supplier product literature Operating manual
For accessories and/or integrated machinery components, observe the relevant
manufacturer's product literature.
1.4 Symbols
Table2: Symbols used in this manual
Symbol Description
✓Conditions which need to be fulfilled before proceeding with the
step-by-step instructions
⊳Safety instructions
⇨Result of an action
⇨Cross-references
1.
2.
Step-by-step instructions
Note
Recommendations and important information on how to handle
the product

1 General
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1.5 Key to safety symbols/markings
Table3: Definition of safety symbols/markings
Symbol Description
!DANGER
DANGER
This signal word indicates a high-risk hazard which, if not avoided,
will result in death or serious injury.
!WARNING
WARNING
This signal word indicates a medium-risk hazard which, if not
avoided, could result in death or serious injury.
CAUTION
CAUTION
This signal word indicates a hazard which, if not avoided, could
result in damage to the machine and its functions.
General hazard
In conjunction with one of the signal words this symbol indicates a
hazard which will or could result in death or serious injury.
Electrical hazard
In conjunction with one of the signal words this symbol indicates a
hazard involving electrical voltage and identifies information about
protection against electrical voltage.
Machine damage
In conjunction with the signal word CAUTION this symbol indicates
a hazard for the machine and its functions.

2 Safety
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2 Safety
!DANGER
All the information contained in this section refers to hazardous situations.
In addition to the present general safety information the action-related safety
information given in the other sections must be observed.
2.1 General
▪This operating manual contains general installation, operating and maintenance
instructions that must be observed to ensure safe operation of the system and
prevent personal injury and damage to property.
▪Comply with all the safety instructions given in the individual sections of this
operating manual.
▪The operating manual must be read and understood by the responsible specialist
personnel/operators prior to installation and commissioning.
▪The contents of this operating manual must be available to the specialist
personnel at the site at all times.
▪Information and markings attached directly to the product must always be
complied with and kept in a perfectly legible condition at all times. This applies
to, for example:
– Markings for connections
– Name plate
▪The operator is responsible for ensuring compliance with all local regulations not
taken into account.
2.2 Intended use
The values specified in the technical product literature for the mains voltage, mains
frequency, ambient temperature and motor current must not be exceeded. The
control unit must only be operated in accordance with the instructions provided in
the operating manual and other applicable documents .
2.3 Personnel qualification and personnel training
All personnel involved must be fully qualified to install, operate, maintain and
inspect the equipment this manual refers to. The responsibilities, competence and
supervision of all personnel involved in installation, operation, maintenance and
inspection must be clearly defined by the operator.
Deficits in knowledge must be rectified by means of training and instruction
provided by sufficiently trained specialist personnel. If required, the operator can
commission the manufacturer/supplier to train the personnel.
Training on the control unit must always be supervised by specialist technical
personnel.
2.4 Consequences and risks caused by non-compliance with this manual
▪Non-compliance with these operating instructions will lead to forfeiture of
warranty cover and of any and all rights to claims for damages.
▪Non-compliance can, for example, have the following consequences:
– Hazards to persons due to electrical, thermal, mechanical and chemical
effects and explosions
– Failure of important product functions
– Failure of prescribed maintenance and servicing practices
– Hazard to the environment due to leakage of hazardous substances

2 Safety
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2.5 Safety awareness
In addition to the safety information contained in this operating manual and the
intended use, the following safety regulations shall be complied with:
▪Accident prevention, health regulations and safety regulations
▪Explosion protection regulations
▪Safety regulations for handling hazardous substances
▪Applicable standards, directives and laws

3 Transport/Storage/Disposal
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3 Transport/Storage/Disposal
3.1 Checking the condition upon delivery
1. On transfer of goods, check each packaging unit for damage.
2. In the event of in-transit damage, assess the exact damage, document it and
notify KSB or the supplying dealer and the insurer about the damage in writing
immediately.
3.2 Transport
CAUTION
Improper transport
Damage to the device!
▷Always transport the device properly and in its original packaging.
▷For transport, observe the transport instructions on the original packaging.
▷Do not throw device.
1. Upon receipt, unpack the device and check for in-transit damage.
2. Report any in-transit damage to the manufacturer immediately.
3. Dispose of packaging material in accordance with local regulations.
3.3 Storage
CAUTION
Damage during storage due to humidity, dirt or vermin
Corrosion/contamination of the control unit!
▷For outdoor storage cover the (packed or unpacked) control unit and
accessories with water-proof material.
If the ambient conditions for storage are met, the function of the control unit is
safeguarded even after a prolonged period of storage. If properly stored indoors, the
equipment is protected for a maximum of 12months.
▪Store the control unit in dry, vibration-free conditions and, if possible, in its
original packaging.
▪Store the control unit in a dry room at constant atmospheric humidity.
▪Prevent excessive fluctuations in atmospheric humidity.
Table4: Ambient conditions for storage
Ambient condition Value
Relative humidity Max. 85% (no condensation)
Ambient temperature -10°C to + 70°C

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3.4 Disposal
Electrical or electronic equipment marked with the adjacent symbol must not be
disposed of in household waste at the end of its service life.
Contact your local waste disposal partner for returns.
If the used electrical or electronic equipment contains personal data, the operator is
responsible for deleting it before the equipment is returned.
NOTE
Due to certain components it contains, the device is classified as special waste and
meets RoHs 2011/65/EC requirements.
Once decommissioned, the device must be properly disposed of in accordance with
local regulations.

4 Description
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4 Description
4.1 General description
▪Alarm switchgear for signalling limit values
4.2 Product information as per Regulation No. 1907/2006(REACH)
For information as per chemicals Regulation (EC) No. 1907/2006 (REACH), see http://
www.ksb.com/reach.
4.3 Designation
Example: AS5
Table5: Designation key
Code Description
AS Type series
5 Code number
4.4 Name plate
1
2
3
4
5
6
ZNI 1448A
2020
00 530 561
1/N/PE/AC 230 V 50 Hz
IP 54
Made in Germany
DC 12 V
Alarmschaltgerät AS5
Johann-Klein-Straße 9
Deutschland
67227 Frankenthal
KSB SE & Co. KGaA
11036786
Fig.1: Name plate (example)
1 Type series, code number 4 Material number
2 Nominal voltage, frequency 5 Year of production
3 Control voltage 6 Enclosure

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4.5 Design details
Design
▪Alarm switchgear for signalling limit values
▪Plastic housing for wall mounting
Signalling functions and display functions
▪Colour-coded LED display
▪Signalling output for connecting external alarm equipment (e.g. horn, alarm
strobe light, alarm combination)
▪Volt-free fault signalling contact for transmitting fault messages (e.g. to a control
station)
Electrical connection
▪1.8m power cable with shockproof plug
▪1~230V AC, 50Hz
▪Enclosure: IP41
4.6 Technical data
Table6: Technical data
Characteristic Value
Alarm switchgear
Nominal operating voltage V [VAC] 1~230
Mains frequency F [Hz] 50
Insulation voltage V [VAC] 630
Enclosure IP41
Safety class II to VDE 0106
Mains type TN
Material Plastic
Colour: RAL 7035, light grey
Rechargeable battery
Battery voltage U [VDC] 12
Stand-by mode in the event of a power failure 6 months
Alarm duration in the event of a power failure 10hours

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4.7 Configuration and function
2
1
4
5
3
6
Fig.2: Description of the alarm switchgear
1 Acknowledgement button 4 Power supply
2 “In operation” indicator (green LED) 5 Contactor connection
3 Fault indicator (red LED) 6 Connection for external alarm
equipment/ volt-free fault signalling
contact
Design The alarm switchgear is designed with a compact plastic housing for wall mounting.
The alarm switchgear serves to signal limit values in combination with a contactor
(e.g. float switch).
Function Limit values are signalled by colour-coded LEDs, external alarm equipment (e.g. horn,
alarm strobe light, alarm combination) or via a volt-free fault signalling contact (e.g.
message to a control station).
The fault indicator (3) signals an active alarm. The “in operation” indicator (2) signals
that the device is mains powered. In the event of a power failure, a maintenance-free
lead gel rechargeable battery provides the alarm switchgear with an emergency
back-up power supply for 10hours.
4.8 Dimensions and weights
Table7: Dimensions and weights
Dimensions H × W × D [kg]
[mm]
170 × 190 × 75 1,85
4.9 Accessories
▪Float switch, circuit open in upper float position
▪Float switch, circuit closed in upper float position
▪M1 contactor
▪Horn
▪Alarm strobe light
▪Alarm combination

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5 Installation at Site
5.1 Safety regulations
DANGER
Incorrect installation
Danger to life!
▷The control unit must be installed in a flood-proof location.
▷Never install the control unit in potentially explosive atmospheres.
▷Integration in external control system: observe the directives for low-voltage
switchgear and controlgear assemblies.
DANGER
Electrical connection work by unqualified personnel
Danger of death from electric shock!
▷Always have the electrical connections installed by a trained and qualified
electrician.
▷Observe regulations IEC60364.
DANGER
Unsuitable electrical installation
Danger to life!
▷Make sure the electrical installation meets the VDE 0100 and IEC 60364
installation rules (i.e. sockets with earthing terminals).
▷Make sure the electric mains is equipped with a residual current device of
maximum 30 mA.
▷If in doubt, contact a specialist electrical company.
5.2 Checks to be carried out prior to installation
Before beginning with the installation check the following:
▪The alarm switchgear is suitable for operation on the power supply network
according to the data on the name plate. (ðSection4.4,Page11)
▪The place of installation is dry.
▪The place of installation is frost-free.
▪The place of installation is protected against flooding.
▪The place of installation is well-ventilated.
▪The place of installation is not potentially explosive.

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5.3 Mounting the alarm switchgear
1
2
Fig.3: Mounting the alarm switchgear
AB
Fig.4: Inserting the fuse protecting the rechargeable battery
üThe installation conditions are taken into account and complied with.
(ðSection5.2,Page14)
üA tool for marking the wall is available.
üAssembly tools are available.
1. Undo the three screws (1) with a suitable tool and keep them in a safe place.
2. Remove the cover (2).
3. Position the alarm switchgear in a suitable area on the wall.
4. Mark the position of the three mounting holes on the wall.
5. Drill the mounting holes.
6. Mount the alarm switchgear.
7. Insert the supplied fuse (typeF1A, 5×20mm) for the rechargeable battery (A)
into the fuse holder on the right-hand side of the charge controller (B).
8. Fit the cover (2) and fasten it with three screws.

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5.4 Electrical connection
DANGER
Electrical connection work by unqualified personnel
Risk of fatal injury due to electric shock!
▷Always have the electrical connections installed by a trained and qualified
electrician.
▷Observe the IEC60364 regulations as well as any regional regulations.
WARNING
Incorrect connection to the mains
Damage to the mains network, short circuit!
▷Observe the technical specifications of the local energy supply companies.
NOTE
Only use the contactors (float switch or M1 contactor) available as accessories.
NOTE
The power cable must have an insulation voltage of at least 500VAC and a
conductor cross-section of 0.75 to 2.5mm2.
If a power cable with earth conductor is used, connect the earth conductor to the
earthing terminal.
12
Fig.5: Preparing the alarm switchgear for the electrical connection
AD C
B
Fig.6: Connecting the cables
üThe mains voltage at the site has been verified against the data on the name
plate. (ðSection4.4,Page11)
üThe wiring diagram is available. (ðSection10.1,Page25)
1. Undo the two screws (1) with a suitable tool and keep them in a safe place.
2. Remove the cover (2).
3. Use a suitable tool to knock out the knock-out openings of the cable entries to
be used at the bottom of the alarm switchgear.
4. Fit the cable gland.

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5. Guide a power cable 1~230VAC, 50Hz through the cable gland and connect it
to the mains terminals (A).
6. Make sure that the sealing elements are properly positioned. Tighten the cable
glands (strain relief).
7. Guide the contactor cable of the float switch or M1 contactor through the cable
gland and connect it to terminals (B).
8. Make sure that the sealing elements are properly positioned. Tighten the cable
glands (strain relief).
9. If applicable, guide the cable of the external alarm equipment (12VDC,
maximum 1.2VA) through the cable gland and connect it to terminals (C).
Observe the polarity as required.
10. If available, guide the cable of a signalling unit or control station (maximum
load 230VAC/ 1A) through the cable gland and connect it to terminals (D).
11. Make sure that the sealing elements are properly positioned. Tighten the cable
glands (strain relief).
12. Fit the cover (2) and fasten it with two screws.
13. Plug in the plug of the power cable.
14. Carry out a functional test. (ðSection6.1.1,Page18)

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6 Commissioning/Start-up/Shutdown
6.1 Commissioning/Start-up
6.1.1 Start-up
DANGER
Operation with open covers
Danger of death from electric shock!
▷Only operate the alarm switchgear with properly mounted covers.
1. Plug the mains plug into the electric mains.
ðThe “in operation” indicator (green LED) lights up.
2. Close the contactor and check the alarm signal.
ðThe fault indicator (red LED) flashes. The connection for external alarm
equipment is supplied with 12V. The volt-free fault signalling NO (normally
open) contacts close and the NC (normally closed) contacts open.
3. Unplug the mains plug. Close the contactor. Check the alarm signal with
emergency back-up power supply (rechargeable battery).
ðThe “in operation” indicator (green LED) extinguishes; the alarm signal
remains lit.
4. Press the acknowledgement button.
ðAlarm signalling via the external alarm equipment and volt-free fault
signalling contacts is stopped. The fault indicator (red LED) keeps flashing.
ðWhen the contactor is no longer active, the fault indicator (red LED)
extinguishes.
NOTE
Before the rechargeable battery is fully functional, it has to be charged on mains
power for at least 10hours while installed in the device.

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6.2 Operating limits
CAUTION
Non-compliance with operating limits
Reduced service life/ failure of the rechargeable battery!
▷Observe the permissible ambient temperature.
▷Perform an annual functional test of the required minimum alarm duration.
6.2.1 Ambient temperature
CAUTION
Operation outside the permissible ambient temperature
Damage to the alarm switchgear!
▷Observe the specified limits for permissible ambient temperatures.
Observe the following parameters and values during operation:
Table8: Permissible ambient temperatures
Permissible ambient temperature Value
Maximum +40°C
Minimum 0°C

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6.3 Shutdown
6.3.1 Shutdown
1. Pull the mains plug out of the socket.
6.3.2 Measures to be taken for shutdown
DANGER
Unintentional contact with live parts
Danger of death from electric shock!
▷De-energise the mains connection.
▷Take steps to ensure that the mains connection cannot be re-energised
unintentionally.
1
2
Fig.7: Preparing the alarm switchgear for removing the fuse
AB
Fig.8: Removing the fuse protecting the rechargeable battery
üThe alarm switchgear has been switched off. (ðSection6.3.1,Page20)
1. Undo the three screws (1) with a suitable tool and keep them in a safe place.
2. Remove the cover (2).
3. Remove the fuse (typeF1A, 5×20mm) for the rechargeable battery (A) from the
fuse holder on the right-hand side of the charge controller (B).
NOTE
Removing the fuse prevents total discharge of the rechargeable battery.
4. Fit the cover (2) and fasten it with three screws.