Manual Start Control Piston - 9 - 6972 - 02e

Service Manual
Motor starter
START CONTROL Piston

9_6972 02 E
Manufacturer:
KAESER KOMPRESSOREN SE
96410 Coburg • PO Box 2143 • GERMANY • Tel. +49-(0)9561-6400 • Fax +49-(0)9561-640130
http://www.kaeser.com
Original instructions
/KKW/CSDAP 1.02 en SBA-START_CONTROL
20161208 094712
Contents
1 Regarding this document

1.1 Using the Document ......................................................................................................... 1
1.2 Copyright .......................................................................................................................... 1
1.3 Symbols and markings ..................................................................................................... 1
1.3.1 Warning notices .................................................................................................. 1
1.3.2 Other notices and symbols ................................................................................. 1
2 Technical Specifications
2.1 Dimensions ...................................................................................................................... 3
2.2 Mass ................................................................................................................................. 3
2.3 Electrical Data .................................................................................................................. 3
2.3.1 Electrical connection ........................................................................................... 3
2.3.2 Power supply specifications ................................................................................ 3
2.4 Temperature ..................................................................................................................... 4
3 Safety and Responsibility
3.1 Dangers ............................................................................................................................ 5
3.2 Intended use .................................................................................................................... 5
3.3 Improper Use ................................................................................................................... 5
3.4 User's Responsibilities ..................................................................................................... 5
3.4.1 Observe statutory and universally accepted regulations. ................................... 5
3.4.2 Qualified personnel ............................................................................................. 5
3.5 Basic Information ............................................................................................................. 6
3.5.1 Safely Dealing with Sources of Danger .............................................................. 6
3.5.2 Safe Use of the Control Cabinet and the Controller ........................................... 7
3.5.3 Danger Areas ...................................................................................................... 7
3.5.4 Organisational Measures .................................................................................... 8
3.6 In Emergency ................................................................................................................... 8
3.6.1 Fire fighting ......................................................................................................... 8
3.7 Safety Signs ..................................................................................................................... 8
3.8 Safety Devices ................................................................................................................. 9
3.9 Environmental Protection ................................................................................................. 9
3.10 Warranty ........................................................................................................................... 9
4 Design and Function
4.1 Control cabinet ................................................................................................................. 10
4.2 Operating modes and control modes ............................................................................... 10
4.2.1 Operating modes ................................................................................................ 10
4.2.2 Control mode ...................................................................................................... 10
4.3 Operating elements .......................................................................................................... 11
4.4 Functions and interconnections ....................................................................................... 12
5 Installation and Operating Conditions
5.1 Safety ............................................................................................................................... 14
5.2 Machine Placement .......................................................................................................... 14
6 Installation
6.1 Safety ............................................................................................................................... 15
6.2 Making the Power Supply Connection ............................................................................. 15
6.3 Mounting the Control Cubicle on the Wall ........................................................................ 16
7 Initial Start-up
7.1 Safety ............................................................................................................................... 17
7.2 Checking Installation and Operating Conditions .............................................................. 17
7.3 Setting the overcurrent relay ............................................................................................ 18
7.4 Initial start-up of START CONTROL ................................................................................ 18
Service Manual Motor starter

9_6972 02 E START CONTROL Piston i
Contents
8 Operation
8.1 Switching On and Off ....................................................................................................... 19
8.1.1 Switching on ....................................................................................................... 19
8.1.2 Switching off ....................................................................................................... 19
8.2 Switching off in an emergency and switching on again .................................................... 19
8.3 Switching on and off from a remote control centre ........................................................... 20
8.4 Resetting Alarms .............................................................................................................. 20
9 Fault Recognition and Rectification
9.1 Basic instructions ............................................................................................................. 21
9.2 Alarms on the Controller (red LED illuminated) ................................................................ 21
9.3 Warnings on the Controller (yellow LED illuminated) ....................................................... 21
10 Maintenance
10.1 Safety ............................................................................................................................... 22
10.2 Maintenance Work ........................................................................................................... 22
10.3 Document maintenance and service work. ...................................................................... 23
11 Spares, Operating Materials, Service
11.1 Note the nameplate .......................................................................................................... 24
11.2 KAESER AIR SERVICE ................................................................................................... 24
11.3 Service Addresses ........................................................................................................... 24
12 Decommissioning, Storage and Transport
12.1 Decommissioning ............................................................................................................. 25
12.2 Storage ............................................................................................................................. 25
12.3 Packing ............................................................................................................................ 25
12.4 Transport .......................................................................................................................... 25
12.4.1 Safety .................................................................................................................. 25
12.4.2 Transporting with a forklift truck .......................................................................... 26
12.4.3 Transporting with a crane ................................................................................... 26
12.5 Disposal ........................................................................................................................... 26
13 Annex
13.1 Electrical diagram ............................................................................................................. 27

ii START CONTROL Piston 9_6972 02 E
List of Illustrations
Fig. 1 View of the control panel ............................................................................................................ 11

Fig. 2 KAESER CONTROL indicators .................................................................................................. 11
Fig. 3 Fixing holes ................................................................................................................................ 16

9_6972 02 E START CONTROL Piston iii
List of Illustrations

iv START CONTROL Piston 9_6972 02 E
List of Tables
Tab. 1 The levels of danger and their meaning ..................................................................................... 1

Tab. 2 Dimensions ................................................................................................................................. 3
Tab. 3 Mass ........................................................................................................................................... 3
Tab. 4 Supply details 400V / 3 / 50Hz .................................................................................................. 4
Tab. 5 Temperature ............................................................................................................................... 4
Tab. 6 Danger Areas ............................................................................................................................. 7
Tab. 7 Safety Signs ............................................................................................................................... 9
Tab. 8 Operating panel .......................................................................................................................... 11
Tab. 9 Indicators .................................................................................................................................... 11
Tab. 10 Installation conditions checklist .................................................................................................. 17
Tab. 11 Machine identification ................................................................................................................. 20
Tab. 12 Remote control identification ...................................................................................................... 20
Tab. 13 KAESER CONTROL alarms ...................................................................................................... 21
Tab. 14 KAESER CONTROL warnings ................................................................................................... 21
Tab. 15 Logged maintenance tasks ........................................................................................................ 23

9_6972 02 E START CONTROL Piston v
List of Tables

vi START CONTROL Piston 9_6972 02 E
1.1 Using the Document

1.1 Using the Document
The service manual is part of the machine. It describes the machine as it was at the time of first
delivery after manufacture.
➤ Keep the service manual in a safe place throughout the life of the machine.
➤ Pass the manual on to the next owner/user of the machine.
➤ Ensure that all amendments received are entered in the manual.
➤ Enter details from the machine nameplate and individual items of equipment in the table in
chapter 2.
1.2 Copyright
This operating manual is protected by copyright. Any queries regarding the use or duplication of
this documentation should be referred to KAESER. Correct use of information will be fully suppor‐
ted.
1.3 Symbols and markings

1.3.1 Warning notices
Warning notices indicate three levels of danger signified by the signal word.
■ DANGER
■ WARNING
■ CAUTION
1. DANGER!
These show the kind of danger and its source.
The possible consequences of ignoring a warning are shown here.
The signal word "DANGER" indicates that death or severe injury can result from ignoring the
warning.
➤ The measures required to protect yourself from danger are shown here.
2. Always read and comply with warning instructions.
Signal word Meaning Consequences of non-observance

DANGER Warns of an imminent threat of danger Death or serious injury may result
WARNING Warns of possible danger Death or serious injury are possible
CAUTION Warns of a possibly dangerous situa‐ Light injuries or material damage are possible
tion
Tab. 1 The levels of danger and their meaning
1.3.2 Other notices and symbols

This symbol refers to particularly important information.

9_6972 02 E START CONTROL Piston 1
1.3 Symbols and markings
Material Here you will find details on special tools, operating materials or spare parts.
Precondition Here you will find conditional requirements necessary to carry out the task.
Here conditions relevant to safety are named that will help you to avoid dangerous situations.
➤ This symbol is is placed by lists of actions comprising one stage of a task.

Information referring to potential problems are identified by a question mark.
The cause is named in the help text ...
➤ ... and a remedy given.
This symbol refers to important information or measures concerning environmental protec‐
tion.
Further information Here, your attention is drawn to further topics.

2 START CONTROL Piston 9_6972 02 E
2.1 Dimensions
2.1 Dimensions
Rated power [kW] Width [mm] Height [mm] Depth [mm]
5.5–18.5 600 600 210
Tab. 2 Dimensions
2.2 Mass
Dimensions [mm] Mass [kg]
600 x 600 26
Tab. 3 Mass
2.3 Electrical Data

2.3.1 Electrical connection
The machine is designed in accordance with the conditions for an electrical power supply specified
in EN 60204-1 (IEC 60204-1) section 4.3.
If no other conditions are specified by the operator, the thresholds described in this standard must
be adhered to.
It is recommended that the user and the supplier reach an agreement on the basis of EN 60204-1,
Annex B.
The machine requires a symmetrical three-phase power supply.
In a symmetrical three phase supply the phase angles and voltages are all the same.
This machine is designed for the operation in an industrial environment with proprietary supply net‐
work separated from the public supply by a transformer or generator.
Incoming line within the switching cabinet to be as short as possible.
If external sensors or communications lines are to be connected to the machine, use shielded ca‐
bles and insert the same through EMC connections into the switching cabinet.
This machine may only be supplied from an earthed TN or TT three-phase supply in which
the neutral point is earthed.
The connection to an IT three-phase supply or a three-phase supply with one earthed phase
is not permitted.
2.3.2 Power supply specifications

The following supply cable conductor cross sections and fusing (slow-blow class gG) are selected
according to German DIN VDE 0100 Part 430 (IEC 60364-4-43) and DIN VDE 0298-4:2013-06
standards for these conditions:
■ Multi-core copper conductors at an operating temperature up to 70 °C
■ Cable length <50 m
■ Ambient temperature of 30 °C
■ Wiring type C, without cable contact

2.4 Temperature
■ Current carrying capacity: Table 3 Column 11

(European Harmonisation Directive HD 60364-5-52: 2011)
■ Bundled cables: Table 21,
─ Single layer on wall or floor
─ Spacing ≥ outside diameter
➤ For other application conditions, check and determine the supply diameters according to
DIN VDE 0100 and DIN VDE 0298-4:2013-06 or the local energy provider.
Other application conditions would include, for example:

■ Higher ambient temperature
■ Other cable installation method
■ Other cable bundling
■ Cable length >50 m
Further information The wiring diagram in chapter 13.1 contains further details of the electric supply connection data.
2.3.2.1 Mains frequency: 50Hz
Rated voltage: 400V / 3 / 50Hz
Rated power [kW] 5.5 7.5 11 15 18.5

Backup fuse [A] 16 16 25 40 40
Supply cable [mm ] 2 4x2.5 4x2.5 4x4 4x6 4x10
Current drawn [A] 11 14 21 29 34
Tab. 4 Supply details 400V / 3 / 50Hz
2.4 Temperature
Date Value
Ambient temperature ±0 °C — +40 °C
Storage temperature -25 °C — +55 °C
Tab. 5 Temperature

3.1 Dangers

3.1 Dangers
Basic information
Information concerning the various forms of danger that can arise during machine operation are
found here.
Basic safety instructions are found in this service manual at the beginning of each chapter in the
section entitled 'Safety'.
Warning instructions are found before a potentially dangerous task.
3.2 Intended use

START CONTROL is designed solely for the control of reciprocating compressors in industrial sec‐
tors. Any other use is considered incorrect. The manufacturer is not liable for any damages that
may result from incorrect use. The user alone is liable for any risks incurred.
➤ Comply with the instructions in this operating manual.
➤ Never operate START CONTROL outside its performance limits and the ambient conditions
laid down.
3.3 Improper Use

➤ Do not operate START CONTROL in areas in which specific requirements with regard to ex‐
plosion protection are in force.
3.4 User's Responsibilities

3.4.1 Observe statutory and universally accepted regulations.
This is, for example, nationally applied European directives and/or valid national legislation, safety
and accident prevention regulations.
➤ Observe relevant statutory and accepted regulations during installation, operation and mainte‐
nance of the equipment.
3.4.2 Qualified personnel

These are people who, by virtue of their training, knowledge and experience as well as their knowl‐
edge of relevant regulations can assess the work to be done and recognise the possible dangers
involved.
Authorised operators possess the following qualifications:

■ are of legal age,
■ are conversant with and adhere to the safety instructions and sections of the service manual
relevant to operation,
■ have received adequate training and authorisation to operate electrical and compressed air de‐
vices.

3.5 Basic Information
Authorised installation and maintenance personnel have the following qualifications:

■ are of legal age,
■ have read, are conversant with and adhere to the safety instructions and sections of the serv‐
ice manual applicable to installation and maintenance,
■ are fully conversant with the safety concepts and regulations of electrical and compressed air
engineering,
■ are able to recognise the possible dangers of electrical and compressed air devices and take
appropriate measures to safeguard persons and property,
■ have received adequate training and authorisation for the safe installation and maintenance on
this equipment.
➤ Ensure that operating, installation and maintenance personnel are qualified and authorised to
carry out their tasks.

The control cabinet is manufactured to the latest engineering standards and acknowledged safety
regulations. Nevertheless, dangers can arise through its operation:
■ Danger to life and limb of the operator or third parties.
■ Impairments to the controller and other material assets.
DANGER
Disregard of these instructions can result in serious injury.
➤ To use the control cabinet safely, read the service manual carefully and take notice of its
contents.
➤ Use the control cabinet only if it is in a technically perfect condition and only for the purpose for
which it is intended; observe all safety measures and the instructions in the service manual.
➤ Immediately rectify (have rectified) any faults that could be detrimental to safety.
3.5.1 Safely Dealing with Sources of Danger

Information concerning the various forms of danger that can arise during machine operation are
found here.
Electricity
➤ Allow only qualified and authorised electricians or trained personnel under the supervision of a
qualified and authorised electrician to carry out work on electrical equipment according to elec‐
trical engineering regulations .
➤ Before every start-up, the user must make sure there is adequate protection against electric
shock from direct or indirect contact.
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that no voltage is
present.
➤ Switch off any external power sources.
These may include devices connected to the floating relay contact.
➤ Use fuses corresponding to the rated power of the connected machines.
➤ Check regularly that all electrical connections are tight and in order.

Unsuitable spare parts
➤ Use only spare parts that have been approved by the manufacturer for this control cabinet.
Unsuitable spare parts compromise the safety of the device.
Conversion or modification of the control cabinet
➤ Do not permit conversion or modification of the equipment as this can compromise function
and safe working.
3.5.2 Safe Use of the Control Cabinet and the Controller

Information on safe conduct when handling the control cabinet and controller is found here.
Transport
➤ Use suitable lifting gear that conforms to local safety regulations.

➤ Allow transport only by personnel trained in the safe movement of goods.
➤ Attach lifting gear only to suitable lifting points.
➤ Be aware of the centre of gravity to avoid tipping.
➤ Make sure the danger zone is clear of personnel.
Installation
➤ Install the control cabinet in a suitable room.

➤ If installed outdoors, the equipment must be protected from frost, direct sunlight, dust, rain and
splashing water.
➤ Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure that the permissible ambient temperature is maintained,
➤ Ensure accessibility so that all work on the equipment can be carried out without danger or hin‐
drance.
Decommissioning, storage, disposal
➤ The control cabinet and all electrical and electronic components must be disposed of in ac‐
cordance with environmental protection regulations.
3.5.3 Danger Areas

The table gives information on the areas dangerous to personnel.
Only authorised personnel may enter these areas.
Activity Danger area Authorised personnel

Transport Within a 2 m radius of the control cabinet. Installation personnel for trans‐
port preparation.
No personnel during transport.
Beneath the lifted control cabinet. No personnel!

3.6 In Emergency
Activity Danger area Authorised personnel

Installation Within the open control cabinet. Installation personnel
Within 1 m radius of the control cabinet and its
supply cables.
Operation During normal operation, there is no danger from Operating personnel
the closed control cabinet.
Maintenance Only within the open control cabinet. Maintenance personnel
Tab. 6 Danger Areas
3.5.4 Organisational Measures

➤ Designate personnel and their responsibilities.
➤ Give clear instructions on reporting faults and damage to the control cabinet and the controller.
➤ Give instructions on fire reporting and fire-fighting measures.
3.6 In Emergency
3.6.1 Fire fighting
Suitable extinguishing agents
■ Foam
■ Carbon dioxide
■ Sand or earth
Unsuitable or unsafe extinguishing agents

■ Strong jet of water
1. Keep calm.
2. Give the alarm.
3. Switch off the power supply disconnecting device, if possible.
4. Move to safety:
■ warn persons in danger
■ help incapacitated persons
■ close the doors
5. Try to extinguish the fire if you have the skill to do so.
3.7 Safety Signs

The table lists the various safety signs used and their meanings.

3.8 Safety Devices
Item Sign Meaning

1 Danger of fatal injury from electric shock!
➤ Before starting any work on electrical equipment:
Switch off and lock out the power supply disconnecting device and check that
no voltage is present.
Tab. 7 Safety Signs
3.8 Safety Devices

Various safety devices ensure safe working with the control cabinet.
➤ Do not change, bypass or disable safety devices.
➤ Check safety devices for correct function regularly.
➤ Do not remove or obliterate labels and notices.
➤ Ensure that labels and notices are clearly legible.
3.9 Environmental Protection

➤ Store and dispose replaced parts in accordance with local environmental protection regula‐
tions.
➤ Observe relevant national regulations.
3.10 Warranty
This service manual contains no independent warranty commitment. Our general terms and condi‐
tions of business apply with regard to warranty.
A condition of our warranty is the specified use of the START CONTROL under observation of the
specific operating conditions.
Due to the multitude applications, the obligation lies with the user to determine the suitability of the
START CONTROL for his specific application.
In addition, we accept no warranty obligation for:

■ the use of unsuitable parts or operating materials,
■ unauthorised modifications,
■ incorrect maintenance,
■ incorrect repair.
Correct maintenance and repair means the use of genuine Kaeser spare parts.
➤ Obtain confirmation from KAESER that your specific operating conditions are suitable.

4.1 Control cabinet

4.1 Control cabinet
The control cabinet, when closed, serves various functions:
■ Protection against contact with components
■ Mounting points for indicators and controls
The smaller control cabinets are suitable for wall mounting. The large control cabinet is a standing
model.
4.2 Operating modes and control modes

The connected machine functions in several operational states. These are called operating modes.
Which operating modes are relevant depends on the machine model and its use.
4.2.1 Operating modes

The following operating modes are possible:
■ LOAD RUN
The inlet valve is open. The machine conveys the relevant medium. The venting valve (if fitted)
is closed.
The drive motor runs at full load.
■ READY:
The inlet valve is closed. The venting valve (if fitted) is open.
The drive motor is stopped.
4.2.2 Control mode

START CONTROL switches the machine between the different operating modes according to cer‐
tain rules (the control mode) depending on which control components (e.g. pressure switch) are fit‐
ted.
START CONTROL works in the following control modes:

■ START/STOP
START/STOP
This control mode is used on the following machines:

■ The machine is not suitable for continuous running.
■ A switch controls the machine between the cut-in and cut-out pressures.
In the START/STOP control mode, the machine toggles between LOAD and READY to maintain
pressure between the preset minimum and maximum values.

4.3 Operating elements
4.3 Operating elements

Operating panel
Fig. 1 View of the control panel
Item Description Function

1 «ON/OFF» switch Switching the machine on and off.
2 «EMERGENCY STOP» button Shuts down the machine in emergency.
3 KAESER CONTROL Safety system monitoring important functions.
4 Operating hours counter Indicates the number of hours the machine has operated.
Tab. 8 Operating panel
KAESER CONTROL safety system
Fig. 2 KAESER CONTROL indicators

1 Controller voltage Lights green when the power supply is switched on.
Extinguishes as soon as an alarm occurs.

4.4 Functions and interconnections

S1 Drive motor:Overcurrent Lights red during overload and shuts down the machine.
S2 Fan:Overcurrent Lights red during overload and shuts down the machine.
S3 Oil level Lights red if the oil level is too low and shuts down the machine.
S4 Temperature Lights red if the compressed air outlet temperature is too high and
shuts down the machine.
S5 – –
S6 – Spare.
S7 – –
S8 Condensate drain Lights red if the condensate drain is defective and shuts down the
machine.
Tab. 9 Indicators

START CONTROL is provided with a number of possible interconnections that serve safe and reli‐
able operation of the machine. The actual number of interconnections available is found in the
electrical diagram.
Unused contacts are normally fitted with wire jumpers.
Operating hours counter
The operating hours counter indicates the actual operating hours of the machine. These can be re‐
ferred to for the planning of maintenance and servicing work.
Drive motor overload
The overcurrent relay protects the drive motor against excess current.
«Remote ON/OFF» switch
An external switch can be connected that allows the machine to be switched on or off from a con‐
trol centre.
External «EMERGENCY STOP»
The machine can be stopped immediately in an emergency by an external «EMERGENCY STOP»

pushbutton without having to be in its close proximity.
External LOAD signal
The machine can be switched to the LOAD operating mode by an external signal. This signal could
be generated by an air network pressure switch or a selection circuit, for example.
Condensate drain at the separator tank
The contacts used for connecting a condensate drain also provide it with a power supply.

Compressed air outlet temperature
Option to connect a temperature gauge switch that monitors the temperature at the compressed air
outlet and shuts down the machine if it overheats.
Airend discharge temperature
Option to connect a temperature gauge switch that monitors the compressor block discharge tem‐
perature and shuts down the machine if it overheats.
Oil pressure or level switch
Depending on the machine version, a signal from an oil pressure switch or oil level monitoring de‐
vice can shut down the machine.
Solenoid valves
Solenoid valves can be connected to control the machine.

According to version, the machine can run in unloaded start mode and/or venting can be control‐
led.
Floating contacts
The following potential-free contacts are provided:

■ Group alarm (“ON” and “no alarm”)
■ Engine running

5.1 Safety

5.1 Safety
➤ Fire and open flame are strictly forbidden.
➤ The machine is not explosion-proof:
Do not operate in areas in which specific requirements with regard to explosion protection are
in force.
For instance, the requirements of ATEX directive 94/9/EC "Equipment and Protective Systems
intended for use in Potentially Explosive Atmospheres".
➤ Ensure that the permissible ambient temperature is maintained,
➤ Keep suitable fire extinguishing agents ready for use.
5.2 Machine Placement

START CONTROL is designed for installation in a suitable room and can be used in general sur‐
roundings in in industrial areas.
➤ Do not hesitate to contact KAESER if you require further information.
Precondition The wall or floor at the place of installation must be firm and capable of bearing the weight of the
control cabinet.
1. If installed outdoors, protect the control cabinet against frost, direct sunlight, dust and rain.
2. Ensure accessibility to the control cabinet so that all work can be carried out without danger or
hindrance.

6 Installation
6.1 Safety
6 Installation
6.1 Safety
Follow the instructions below for safe installation.
Basic safety instructions
1. Follow the instructions in chapter 3 'Safety and Responsibility'.

2. Installation work may only be carried out by authorized personnel.
3. Before switching on, make sure that:
■ no personnel are working on the control cabinet,
■ the control cabinet access door is closed.
Working on live components
1. Work on electrical equipment may only be carried out by authorized electricians.

2. Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.
3. Check that there is no voltage on floating relay contacts.
Further information Details of authorized personnel are found in chapter 3.4.2.

Details of dangers and their avoidance are found in chapter 3.1.
6.2 Making the Power Supply Connection

Precondition All three phases of the power supply are isolated,
the disconnect device is locked in the off position,
a check has been made that no voltage is present.
1. Have the power supply connected by authorized installation personnel or an authorized electri‐
cian only.
2. Carry out safety measures as stipulated in relevant regulations (IEC 364, for example) and in
national accident prevention regulations (BGV A2 in Germany). In addition, observe the regula‐
tions of the local electricity supplier.
3. Check the permitted disconnect time for the overload protection cutout if a fault arises.
4. Select supply cable conductor cross-sections and fusing in accordance with local regulations.
5. The user must provide START CONTROL with a lockable power supply disconnecting device.
This could be, for example, a load disconnect switch with fused input. If a circuit breaker is
used it must be suitable for the machine's motor starting characteristics.
6. DANGER!
Danger of fatal injury from electric shock!
➤ Switch off and lock out the power supply disconnecting device and check that no voltage
is present.
7. Connect the machine to the power supply.
Further information The electrical diagram in chapter 13.1 contains further details of the power supply connection.

6 Installation
6.3 Mounting the Control Cubicle on the Wall
6.3 Mounting the Control Cubicle on the Wall

The control cabinets for wall mounting can be affixed with 4 screws. The type of fixings used
should suit the structure of the wall and the weight of the control cabinet.
Precondition The control cabinet is suited to wall mounting.
Fig. 3 Fixing holes
➤ Affix the control cubicle to the wall with suitable fixings.

7 Initial Start-up
7.1 Safety
7 Initial Start-up
7.1 Safety
Instructions for Safe Initial Start-up of the Machine.

2. Have installation work carried out by authorized installation personnel only.
■ No personnel are working on the machine and on the control cabinet.

voltage is present.
Working on the drive system
➤ Switch off and lock out the power supply disconnecting (isolating) device and check that no
voltage is present.

7.2 Checking Installation and Operating Conditions

➤ Check and confirm all the items in the checklist before initial start-up of the machine:
To be checked See chapter OK?

➤ Are the operators fully conversant with safety regulations? —
➤ Have all the installation conditions been fulfilled? 5
➤ Is a user's lockable power supply disconnecting device installed? 6.2
➤ Does the power supply conform to the specifications on the nameplate? —
➤ Are the power supply cable core cross-sections and fuse ratings ade‐ —
quate?
Tab. 10 Installation conditions checklist

7 Initial Start-up
7.3 Setting the overcurrent relay
7.3 Setting the overcurrent relay

Star-delta start
In the star-delta configuration the phase current is fed via the overcurrent relay. This phase current
is 0.58-times the rated motor current (see nameplate).
To prevent voltage fluctuations, temperature influences or component tolerances triggering
the overcurrent relay, the setting can be higher than the arithmetical phase current.
➤ Check the overcurrent relay setting.

The overcurrent relay shuts the machine down despite being correctly set?
➤ Contact the authorised KAESER SERVICE.
7.4 Initial start-up of START CONTROL

As soon as START CONTROL has been started for the first time,check the interconnected sys‐
tems for correct function.
Precondition The machine connected is ready for operation.

The control cabinet is wired according to the electrical diagram.
1. Switch on the START CONTROL with the «ON/OFF» switch.

All LEDs on KAESER CONTROL light up for a short period as a function check.
2. If alarms or warnings are indicated:
Correct the fault and switch theSTART CONTROLon again.
As soon as an alarm appears on START CONTROL, the machine is shut down and the con‐
troller is blocked.
➤ Switch START CONTROL off and then on again with the «ON/OFF» switch.
3. Check the machine's direction of rotation.
➤ Follow the instructions in the machine's service manual.
Result START CONTROL is ready for operation.

8 Operation
8.1 Switching On and Off
8 Operation
8.1 Switching On and Off
Always switch the machine on and off with the «ON/OFF» switch.
A power supply disconnecting device has been installed by the user.
8.1.1 Switching on
Precondition No personnel are working on START CONTROL and the controlled machine
The control cabinet access door is closed and locked.
1. Switch on the power supply disconnecting device.

The green Controller Power LED ( 1 , see fig. 2) lights continuously.
2. Switch the «ON/OFF» switch ( 1 , see fig. 1) to the ON position.
The controlled machine is switched on and starts, assuming start conditions allow.
If a power failure occurs, the controlled machine is not prevented from re-starting automati‐
cally.
It can start automatically again as soon as power is restored.
8.1.2 Switching off

1. Switch the «ON/OFF» switch to the OFF position.
2. Switch off and lock out the power supply disconnecting device.
The machine is switched off and isolated from the mains supply. The Controller Power LED ex‐
tinguishes.
8.2 Switching off in an emergency and switching on again

The «EMERGENCY STOP» pushbutton is located on the control panel (2, see fig. 1)
Switching off
➤ Press «EMERGENCY STOP».

The «EMERGENCY STOP» pushbutton remains locked after actuation.
The power supply to the controlled machine is interrupted and the machine is secured against
an automatic restart.
Switching on
Precondition The fault has been rectified.

START CONTROL is switched off.
➤ Turn the «EMERGENCY STOP» pushbutton in the direction of the arrow to unlock it.
The machine can now be started again.

8 Operation
8.3 Switching on and off from a remote control centre
8.3 Switching on and off from a remote control centre

Precondition A link to the remote control centre exists.
The start device in the remote control centre is switched off.
1. Attach an easily seen notice to the machine that warns of remote operation.
DANGER!
This machine is remotely controlled and can start automatically at any time.
Tab. 11 Machine identification
2. Label the starting device in the remote control centre as follows:
DANGER!
➤ Before starting, make sure that no one is working on the machine and that it can be safely
started.
Tab. 12 Remote control identification
3. Switch on the machine from the START CONTROL.

The machine will start as soon as the start device in the remote control centre switches on the
machine.
8.4 Resetting Alarms

As soon as an alarm appears on START CONTROL, the machine is shut down and the controller
is blocked.
Precondition The fault has been rectified
➤ Switch START CONTROL off and then on again with the «ON/OFF» switch.
The Controller Power LED illuminates.
The machine is now ready to start again.

9.1 Basic instructions

9.1 Basic instructions
The following tables are intended to assist in locating faults.
The individual measures valid for your machine are dependent on the functions installed.
Error messages are classified in these categories:

■ Fault: Red LED flashes - see chapter 9.2.
■ Warning: Yellow LED lights- see chapter 9.3.
1. Do not attempt fault rectification measures other than those given in this manual!
2. In all other cases:
Have the fault rectified by an authorised KAESER SERVICE technician.
9.2 Alarms on the Controller (red LED illuminated)

Refer to fig. 2 for these messages
Message Possible cause Remedy

S1 The motor is overloaded. Check the setting of the overcurrent relay.
S2 – –
S3 Fluid level too low. Top up the oil.
S4 Compressor outlet air temperature is too Check operating conditions.
high. Ensure adequate ventilation.
S8 Fault at condensate drain Check the condensate drain.
Tab. 13 KAESER CONTROL alarms
9.3 Warnings on the Controller (yellow LED illuminated)

Refer to fig. 2 for these messages
➤ Enter your own data for S5, S6, S7 messages as these spare contacts can be freely
assigned.
Message Possible cause Remedy

S5 – –
S6 – –
S7 – –
Tab. 14 KAESER CONTROL warnings

10 Maintenance
10.1 Safety
10 Maintenance
10.1 Safety
Follow the instructions below to ensure safe machine maintenance.

2. Maintenance work may only be carried out by authorized personnel.
■ No personnel are working on the controller and the controlled machine,
■ the control cabinet access door is closed.

voltage is present.

10.2 Maintenance Work

START CONTROL contains no components that are subject to regular maintenance work.
➤ Only authorized KAESER service representatives may carry out repair work.

10 Maintenance
10.3 Document maintenance and service work.
10.3 Document maintenance and service work.

Machine number:
➤ Enter maintenance and service work carried out in the list.
Date Maintenance task carried out Operating hours Signature
Tab. 15 Logged maintenance tasks

11.1 Note the nameplate

11.1 Note the nameplate
The nameplate contains all information to identify your machine. This information is essential to us
in order to provide you with optimal service.
➤ Please give the information from the nameplate with every enquiry and order for spares.
11.2 KAESER AIR SERVICE

KAESER AIR SERVICE offers:
■ Authorised service technicians with KAESER factory training
■ Increased operational reliability ensured by preventive maintenance
■ Energy savings achieved by avoidance of pressure losses
■ optimum conditions for operation of the compressed air system,
■ The security of genuine KAESER spares.
■ Increased legal certainty as all regulations are kept to.
➤ It make sense to sign a KAESER AIR SERVICE maintenance agreement.

Your advantage:
lower costs and higher compressed air availability.
11.3 Service Addresses

Addresses of KAESER agents are given at the end of this manual.

12.1 Decommissioning

12.1 Decommissioning
This is necessary under the following circumstances:
■ The controller is temporarily not needed.
■ The controller is to be moved to another location.
■ The controller is to be scrapped.
1. Isolate the controller from all power phases.

2. Switch off external power sources.
3. Ensure that the power sources cannot be switched on again (locked off).
4. Check that all contacts are free of voltage.
12.2 Storage
Moisture can lead to corrosion, particularly on the surfaces of the control cabinet and contacts.
Advice can be obtained from KAESER on storage and commissioning.
1. Lay or stand the control cabinet in a dry room.

2. Maintain storage temperature.
12.3 Packing
Suitable packing is required for overland transport to protect the equipment from mechanical dam‐
age. A wooden crate may be required for larger control cabinets.
Consult an authorized KAESER Service agent for advice on packing for sea or air transport.
Material Desiccant (silica gel or similar)

Plastic sheeting
Transport palette or wooden crate (if required)
Precondition The controller is decommissioned and dry.
1. Provide the cabinet with sufficient desiccant and screw to a palette if necessary.
2. Wrap the cabinet in plastic sheeting.
3. Provide a wooden crate if necessary.
12.4 Transport
12.4.1 Safety
Mass and centre of gravity determine the most suitable method of transportation.
Precondition Transport only by forklift truck or lifting gear only by personnel trained in the safe transportation of
loads.

12.5 Disposal
➤ Make sure the danger area is clear of personnel.
12.4.2 Transporting with a forklift truck

Precondition The forks are fully under the equipment
➤ Use lifting gear correctly and lift the control cabinet carefully.
12.4.3 Transporting with a crane

Suitable lifting gear ensures correct transportation.
The lifting slings must be fully under the control cabinet.
Precondition The lifting gear complies with local safety regulations.

No pressure should bear on the sides of the cabinet.
➤ Use the lifting gear correctly and lift the carefully.
12.5 Disposal
The controller must be completely severed from all connections for disposal.
Precondition The controller is decommissioned.
➤ Hand the controller over to an authorized disposal expert.

13 Annex
13.1 Electrical diagram
13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex

13 Annex


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Service Manual

START CONTROL Piston

1 Regarding this document

Service Manual Motor starter

Service Manual Motor starter

Fig. 1 View of the control panel ............................................................................................................ 11

Service Manual Motor starter

Service Manual Motor starter

Tab. 1 The levels of danger and their meaning ..................................................................................... 1

Service Manual Motor starter

Service Manual Motor starter

1 Regarding this document

1.3 Symbols and markings

Signal word Meaning Consequences of non-observance

Tab. 1 The levels of danger and their meaning

1.3.2 Other notices and symbols

Service Manual Motor starter

➤ This symbol is is placed by lists of actions comprising one stage of a task.

Further information Here, your attention is drawn to further topics.

Service Manual Motor starter

2.3 Electrical Data

2.3.2 Power supply specifications

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■ Current carrying capacity: Table 3 Column 11

Other application conditions would include, for example:

2.3.2.1 Mains frequency: 50Hz

Rated voltage: 400V / 3 / 50Hz

Rated power [kW] 5.5 7.5 11 15 18.5

Tab. 4 Supply details 400V / 3 / 50Hz

Service Manual Motor starter

3 Safety and Responsibility

3.2 Intended use

3.3 Improper Use

3.4 User's Responsibilities

3.4.2 Qualified personnel

Authorised operators possess the following qualifications:

Service Manual Motor starter

Authorised installation and maintenance personnel have the following qualifications:

3.5 Basic Information

3.5.1 Safely Dealing with Sources of Danger

Service Manual Motor starter

Unsuitable spare parts

Conversion or modification of the control cabinet

3.5.2 Safe Use of the Control Cabinet and the Controller

➤ Use suitable lifting gear that conforms to local safety regulations.

➤ Install the control cabinet in a suitable room.

Decommissioning, storage, disposal

3.5.3 Danger Areas

Activity Danger area Authorised personnel

Service Manual Motor starter

Activity Danger area Authorised personnel

Tab. 6 Danger Areas

3.5.4 Organisational Measures

Unsuitable or unsafe extinguishing agents

3.7 Safety Signs

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Item Sign Meaning

Tab. 7 Safety Signs

3.8 Safety Devices

3.9 Environmental Protection

In addition, we accept no warranty obligation for:

Service Manual Motor starter

4 Design and Function