DAB E-BOX PLUS Operating and maintenance manual
INSTRUCTIONS FOR INSTALLATION AND MAINTENANCE (GB)
E.Box Plus
E.Box Plus D
E.Box Basic
E.Box Basic D
Pag. 62
ENGLISH
ENGLISH
62
INDEX
KEY..................................................................................................................................................................67
WARNINGS .....................................................................................................................................................67
RESPONSIBILITY ...........................................................................................................................................67
1GENERAL ................................................................................................................................................68
1.1Technical characteristics................................................................................................................68
1.2Protections.......................................................................................................................................68
2INSTALLATION........................................................................................................................................69
2.1Electrical connections.....................................................................................................................69
2.1.1 Instrumental checks to be carried out by the installer ...................................................................69
2.1.2 Boards and connections.................................................................................................................70
2.2Electrical connection of the pumps...............................................................................................72
Connection of three-phase pumps............................................................................................................72
Connection of single-phase pumps with internal capacitor. .....................................................................72
Connection of single-phase pumps with external capacitor. ....................................................................72
2.3Power supply electrical connection ..............................................................................................73
3FRONT PANEL ........................................................................................................................................74
4PANEL INTERNAL REGULATING BOARD ...........................................................................................75
4.1Trimmer for regulating the system (Imax – SP – DP)...................................................................75
4.2Dip-switch for selecting functions (DS_A – DS_B)......................................................................76
5PRESSURE BOOSTING FUNCTION......................................................................................................77
5.1Expansion vessel.............................................................................................................................77
5.2Electrical connections of pump and supply.................................................................................77
5.3Connection of additional protections: high pressure, low pressure and motor thermal
protection....................................................................................................................................................77
5.4Connection of the alarm outputs ...................................................................................................78
5.5Operation with pressure sensor (recommended choice)............................................................78
5.6Connection of the pressure sensor...............................................................................................78
5.7Operation with pressure switches.................................................................................................78
5.8Setting with the display, wizard.....................................................................................................79
5.9Setting with a pressure sensor......................................................................................................80
5.10Configuration with pressure switches ..........................................................................................81
5.11Setting the E.box with dip switches ..............................................................................................81
5.12Activation of the set ........................................................................................................................82
5.13Regulating the rated current of the pumps (Imax), Set point (SP) and differential restarting
pressure (DP)..............................................................................................................................................82
5.14System operation.............................................................................................................................83
Pressure switches:....................................................................................................................................83
Pressure sensor:.......................................................................................................................................83
6FILLING FUNCTION ................................................................................................................................84
6.1Electrical connections of pump and supply.................................................................................84
6.2Control inputs ..................................................................................................................................84
6.3Connection of additional protections: overflow, water lack, motor thermal protection..........84
6.4Connection of the alarm outputs ...................................................................................................86
6.5Connection of floats or level probes.............................................................................................86
6.6Depth sensor connection ...............................................................................................................86
6.7Setting with the display, wizard.....................................................................................................87
6.8Configuration of floats or level probes .........................................................................................87
6.9Configuration with a depth sensor................................................................................................88
6.10Setting the E.box with dip switches ..............................................................................................89
6.11Activation of the set ........................................................................................................................89
6.12Regulating the rated current of the pumps (Imax) and the pump starting and stopping
levels (only with depth sensor connected)..............................................................................................89
6.13System operation: ...........................................................................................................................90
Operation with 2 floats or level probes .....................................................................................................90
Operation with 3 floats or level probes .....................................................................................................90
Operation with depth sensor and display..................................................................................................90
Operation with depth sensor without display............................................................................................90
7Draining function....................................................................................................................................92
7.1Electrical connections of pump and supply.................................................................................92
7.2Control inputs ..................................................................................................................................92
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7.3Connection of additional protections: overflow, water lack, motor thermal protection..........92
7.4Connection of the alarm outputs ...................................................................................................94
7.5Connection of floats or level probes.............................................................................................94
7.6Depth sensor connection ...............................................................................................................94
7.7Setting with the display, wizard.....................................................................................................95
7.8Configuration of floats or level probes .........................................................................................95
7.9Configuration with a depth sensor................................................................................................96
7.10Setting the E.box with dip switches ..............................................................................................97
7.11Activation of the set ........................................................................................................................97
7.12Regulating the rated current of the pumps (Imax) and the pump starting and stopping
levels (only with depth sensor connected)..............................................................................................98
7.13System operation: ...........................................................................................................................98
Operation with 2 floats or level probes .....................................................................................................98
Operation with 3 floats or level probes .....................................................................................................98
Operation with depth sensor and display..................................................................................................99
Operation with depth sensor without display............................................................................................99
8KIWA PRESSURE BOOSTING FUNCTION..........................................................................................100
8.1Expansion vessel...........................................................................................................................100
8.2Electrical connections of pump and supply...............................................................................100
8.3Connection of additional protections: high pressure and motor thermal protection............100
8.4Connection of the alarm outputs .................................................................................................101
8.5Operation with pressure sensor (recommended choice)..........................................................101
8.6Connection of the pressure sensor.............................................................................................101
8.7Operation with pressure switches...............................................................................................101
8.8Connection of pressure switches................................................................................................101
8.9Connecting the low-pressure pressure switch ..........................................................................102
8.10Setting with the display, wizard...................................................................................................102
8.11Setting with a pressure sensor:...................................................................................................103
8.12Configuration with pressure switches:.......................................................................................103
8.13System status in Kiwa mode........................................................................................................104
8.14Setting the E.box with dip switches ............................................................................................104
8.15Activation of the set ......................................................................................................................104
8.16Regulating the rated current of the pumps (Imax), Set point (SP) and differential restarting
pressure (DP)............................................................................................................................................105
8.17System operation...........................................................................................................................105
Pressure switches:..................................................................................................................................105
Pressure sensor:.....................................................................................................................................105
9THE KEYPAD AND THE DISPLAY.......................................................................................................107
9.1Status line.......................................................................................................................................108
9.2Menus .............................................................................................................................................108
9.3Access to the menus.....................................................................................................................108
Direct access with a combination of keys...............................................................................................108
Access by name with a drop-down menu...............................................................................................110
9.4MEANING OF THE INDIVIDUAL PARAMETERS .........................................................................110
9.4.1 USER MENU ................................................................................................................................110
VP: Pressure display...............................................................................................................................110
C1: Display of the phase current of pump P1.........................................................................................110
C2: Display of the phase current of pump P2.........................................................................................110
PO1: Display of the power absorbed by pump P1..................................................................................110
PO2: Display of the power absorbed by pump P2..................................................................................110
VE: System monitor................................................................................................................................110
9.4.2 MONITOR MENU .........................................................................................................................111
FF: Fault log display................................................................................................................................111
CT: Display contrast................................................................................................................................111
LA: Language..........................................................................................................................................111
HS: System operating hours...................................................................................................................111
H1: Pump P1 operating hours ................................................................................................................111
H2: Pump P2 operating hours ................................................................................................................111
9.4.3 SETPOINT MENU ........................................................................................................................111
SP: Setting the Set Point pressure (only in pressure boosting and in KIWA pressure boosting with ....111
pressure sensor).....................................................................................................................................111
RP: Setting the Pressure Differential (only in pressure boosting and in KIWA pressure boosting.........111
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64
with pressure sensor)..............................................................................................................................111
HC: Pump P2 starting level (only in drainage or filling with depth sensor).............................................111
HB: Pump P1 starting level (only in drainage or filling with depth sensor).............................................111
HA: Pumps stopping level (only in drainage or filling with depth sensor)...............................................112
9.4.4 INSTALLER MENU......................................................................................................................112
RC: Setting the rated current of the electropump...................................................................................112
MF: Operating mode...............................................................................................................................112
MC: Control devices................................................................................................................................112
GS: Protection devices (only in drainage or filling or with depth sensor)...............................................112
PR: Type of sensor used (only if a pressure or depth sensor is used)...................................................112
MS: Measuring system ...........................................................................................................................112
SO: Dry running factor............................................................................................................................112
MP: Minimum pressure threshold (only in pressure boosting and KIWA pressure boosting)................112
OD: Expansion vessel size (only in pressure boosting and KIWA pressure boosting)..........................112
EP: Pump exclusion................................................................................................................................112
9.4.5 TECHNICAL ASSISTANCE MENU.............................................................................................113
TB: Water lack blockage time.................................................................................................................113
T1: Switch-off time after the low pressure signal (only in pressure boosting and KIWA pressure.........113
boosting).................................................................................................................................................113
T2: Switch-off delay time (only in KIWA pressure boosting)...................................................................113
ET: Exchange mode ...............................................................................................................................113
AL: Anti-leakage......................................................................................................................................113
AL: Anti-blocking (only in drainage)........................................................................................................113
TH: Tank height (only in filling or drainage mode with a depth sensor) .................................................113
ML: Maximum level alarm (only in filling or drainage mode with a depth sensor)..................................113
LL: Minimum level alarm (only in filling or drainage mode with a depth sensor)....................................113
RF: Reset fault & warning.......................................................................................................................113
PW: Setting the password ......................................................................................................................113
10PANEL PROTECTIONS AND ALARMS ...............................................................................................114
10.1Errors indicated by alarm leds and relays..................................................................................114
10.2Digital inputs R and N protection /alarm.....................................................................................116
- Relay/remote control switch alarm .......................................................................................................116
- Pump disconnected..............................................................................................................................116
- Dry running protection/alarm................................................................................................................117
- Protection against too frequent starts...................................................................................................117
- Current overload protection/alarm (overload protection)......................................................................117
- Pressure or depth sensor alarm...........................................................................................................117
- Floats and/or probes incoherence alarm..............................................................................................117
- Dip-Switch alarm...................................................................................................................................117
- Error alarm............................................................................................................................................117
- Input voltage.........................................................................................................................................117
- Voltage selector error ...........................................................................................................................118
- Voltage Error.........................................................................................................................................118
- Internal error.........................................................................................................................................118
- General pump error P1 + P2 ................................................................................................................118
10.3Alarms shown on the display.......................................................................................................118
10.3.1 Alarms indicated on the display..............................................................................................118
- JR: Relay/remote control switch stuck alarm .......................................................................................119
- NC: Pump Disconnected .....................................................................................................................119
- BL: Dry running protection/alarm..........................................................................................................119
- LK: Protection against too frequent starts ............................................................................................120
- OC: Current overload protection/alarm (overload protection) ..............................................................120
- RI: RI alarms.........................................................................................................................................120
- NI: NI alarms.........................................................................................................................................120
- HL: Maximum level alarm.....................................................................................................................121
- LL: Minimum level alarm.......................................................................................................................121
- BP1/BP2: Pressure sensor / depth sensor alarm.................................................................................121
- FI: Floats or level probes state incoherence ........................................................................................121
- DS: Dip Switch alarm............................................................................................................................121
- W1: Trimmer SP...................................................................................................................................121
- W2: Trimmer DP...................................................................................................................................121
- W3: Trimmer Imax................................................................................................................................121
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- PK: Key error........................................................................................................................................122
- NL: Input voltage error..........................................................................................................................122
- VS: Voltage selector error ....................................................................................................................122
- V0..V15: Voltage error..........................................................................................................................122
- OM: Changed operating mode.............................................................................................................122
- E0..E15: Internal error ..........................................................................................................................122
11RESET AND FACTORY SETTINGS......................................................................................................122
11.1General system reset ....................................................................................................................122
11.2Restoring the factory settings......................................................................................................122
INDEX OF TABLES
Table 1: Technical data....................................................................................................................................68
Table 2: Pressure boosting operation with pressure switches.........................................................................83
Table 3: Pressure boosting operation standard vessel < 100 litres.................................................................83
Table 4: Operation with additional expansion vessel > 100 litres....................................................................83
Table 5: Filling operation with 2 floats..............................................................................................................90
Table 6: Filling operation with 3 floats..............................................................................................................90
Table 7: Operation with depth sensor, without display....................................................................................91
Table 8: Filling operation with 2 floats..............................................................................................................98
Table 9: Filling operation with 3 floats..............................................................................................................98
Table 10: Drainage with depth sensor, without display ...................................................................................99
Table 11: Pressure boosting operation with pressure switches.....................................................................105
Table 12: Pressure boosting operation standard vessel < 100 litres.............................................................106
Table 13: Operation with additional expansion vessel > 100 litres................................................................106
Table 14: Key functions..................................................................................................................................108
Table 15: Access to the menus......................................................................................................................109
Table 16: Menu structure...............................................................................................................................110
Table 17: General table of alarms: signals and contacts...............................................................................115
Table 18: Digital inputs R and N protection /alarm ........................................................................................116
Table 19: E.Box errors shown on the display ................................................................................................119
Table 20: RI alarms........................................................................................................................................120
Table 21: NI alarms........................................................................................................................................121
INDEX OF FIGURES
Figure 1: E.box Basic Board ............................................................................................................................70
Figure 2: E.Box Plus Board..............................................................................................................................71
Figure 3: Electrical connection of pumps.........................................................................................................72
Figure 4: Connection of pump external capacitors ..........................................................................................73
Figure 5: Electrical connection to the supply line.............................................................................................73
Figure 6: Display label, present only on plus models ......................................................................................74
Figure 7: Front label.........................................................................................................................................74
Figure 8: Inputs and outputs ............................................................................................................................77
Figure 9: Thermal protection inputs KK ...........................................................................................................78
Figure 10: Pressure sensor connection 4..20Ma.............................................................................................78
Figure 11: Terminals for connecting the pressure switches ............................................................................79
Figure 12: Configuration with a pressure sensor.............................................................................................80
Figure 13: Configuration with pressure switches.............................................................................................81
Figure 14: Dip switches for pressure boosting.................................................................................................81
Figure 15: Enabling P1 and P2........................................................................................................................82
Figure 16: Regulating: Imax, SP and DP.........................................................................................................82
Figura 17: Regulation with expansion vessel < 100 litres................................................................................83
Figura 18: Regulation with expansion vessel > 100 litres................................................................................83
Figure 19: Diagram of filling system inputs......................................................................................................84
Figure 20: Inputs and protections ....................................................................................................................85
Figure 21: Thermal protection inputs KK .........................................................................................................85
Figure 22: Inputs..............................................................................................................................................86
Figure 23: Depth sensor connection................................................................................................................86
Figure 24: Configuration of Filling with floats or level probes..........................................................................87
Figure 25: System status in filling mode, with floats or level probes as control inputs....................................87
Figure 26: A System status with depth sensor only, B depth sensor and floats, C depth sensor and level
probes.......................................................................................................................................................88
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Figure 27: Setting the filling dip switches.........................................................................................................89
Figure 28: Enabling P1 and P2........................................................................................................................89
Figure 29: Regulating the rated current SP and DP........................................................................................90
Figure 30: Filling with a depth sensor..............................................................................................................91
Figure 31: Draining system diagram................................................................................................................92
Figure 32: Position of inputs and alarms..........................................................................................................93
Figure 33: Thermal protection inputs KK .........................................................................................................93
Figure 34: Inputs..............................................................................................................................................94
Figure 35: Depth sensor connection................................................................................................................94
Figure 36: Configuration of Drainage floats or level probes ............................................................................95
Figure 37: System status in drainage mode, A with level probes. B with floats ..............................................95
Figure 38: Configuration with only a depth sensor...........................................................................................96
Figure 39: System status in configurations: A with only depth sensor, B: depth sensor and floats, C depth
sensor and level probes............................................................................................................................97
Figure 40: Setting the Drainage dip switches ..................................................................................................97
Figure 41: Enabling P1 and P2........................................................................................................................97
Figure 42: Regulating the rated current SP and DP........................................................................................98
Figure 43: Drainage with a depth sensor.........................................................................................................99
Figure 44: Inputs............................................................................................................................................100
Figure 45: Thermal protection inputs KK .......................................................................................................101
Figure 46: Connection of the pressure sensor...............................................................................................101
Figure 47: Pressure switch terminal board ....................................................................................................102
Figure 48: KIWA pressure boosting with pressure sensor.............................................................................103
Figure 49: Kiwa configuration with pressure switches...................................................................................103
Figure 50: System status in KIWA mode.......................................................................................................104
Figure 51: Dip switches for KIWA pressure boosting ....................................................................................104
Figure 52: enabling P1 and P2.......................................................................................................................104
Figure 53: Regulating the rated current SP and DP......................................................................................105
Figura 54: Regulation with expansion vessel < 100 litres..............................................................................106
Figura 55: Regulation with expansion vessel > 100 litres..............................................................................106
Figure 56: Label and keys..............................................................................................................................107
Figure 57: Label, keys and display ................................................................................................................108
Figure 58: Selection of the drop-down menus...............................................................................................110
Figure 59: Errors in the memory ....................................................................................................................111
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KEY
The following symbols have been used in the discussion:
Situation of general danger. Failure to respect the instructions that follow may cause harm to persons
and property.
Situation of electric shock hazard. Failure to respect the instructions that follow may cause a situation of
grave risk for personal safety.
WARNINGS
Read this documentation carefully before installation.
Installation and operation must comply with the local safety regulations in force in the country in which
the product is installed. Everything must be done in a workmanlike manner.
Failure to respect the safety regulations not only causes risk to personal safety and damage to the
equipment, but invalidates every right to assistance under guarantee.
Skilled personnel
It is advisable that installation be carried out by competent, skilled personnel in possession of the
technical qualifications required by the specific legislation in force.
The term skilled personnel means persons whose training, experience and instruction, as well as their
knowledge of the respective standards and requirements for accident prevention and working conditions,
have been approved by the person in charge of plant safety, authorizing them to perform all the
necessary activities, during which they are able to recognize and avoid all dangers. (IEC 60730).
Safety
Use is allowed only if the electric system is in possession of safety precautions in accordance with the
regulations in force in the country where the product is installed. Check that the panel has not been
damaged.
In particular, check that all the internal parts of the panel (components, leads, etc.) are completely free from
traces of humidity, oxide or dirt: if necessary, clean accurately and check the efficiency of all the components in
the panel. If necessary, replace any parts that are not perfectly efficient.
It is indispensable to check that all the panel leads are correctly tightened in the respective clamps.
In the event of a long period of inactivity (or when any component has been replaced), it is advisable to
perform on the panel all the checks indicated by standard EN 60730-1.
Failure to observe the warnings may create situations of risk for persons or property and will void the product
guarantee.
RESPONSIBILITY
The Manufacturer does not vouch for correct operation of the electropumps or answer for any damage that
they may cause if they have been tampered with, modified and/or run outside the recommended work range
or in contrast with other indications given in this manual.
The Manufacturer declines all responsibility for possible errors in this instructions manual, if due to misprints or errors
in copying. The Manufacturer reserves the right to make any modifications to products that it may consider necessary
or useful, without affecting their essential characteristics
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68
1 GENERAL
This documentation supplies the general indications for the storage, installation and use of the E.box electric panel,
which has been designed and made for the control and protection of Sets of 1 or 2 pumps for: drainage (emptying),
filling and pressure boosting.
WHERE TO INSTALL THE PANEL:
It is good practice to install the panel correctly, taking particular care to comply with the following indications.
the panel must be kept in a completely dry place, far from sources of heat;
the electric panel must be perfectly closed and isolated from the outside environment, so as to avoid the entry of
insects, humidity and dust which could damage the electrical components, jeopardising their regular operation.
Choose the sensors with a grade of protection suitable for the place in which they will be positioned.
1.1 Technical characteristics
E.box Plus
E.box Plus D E.box Basic
E.box Basic D
Power supply
+10% - 15% 3 x 400V
3 x 230 V
1 x 230V
1 x 230V
Frequency 50/60Hz 50/60Hz
Grade of protection IP 55 IP55
No. pumps that can be connected: 1 or 2 1 or 2
Maximum rated current of the pumps 12A 12A
Maximum rated power of the pumps 5.5kW at 3 x
400V
3.2kW at 3 x
230V
2.2kW at 1x230V
2.2kW at 1 x
230V
Environment temperature -10 ÷ 40°C 10 ÷ 40°C
Storage temperature -25°C ÷ 55°C -25°C ÷ 55°C
Air relative humidity 50% at 40°C
90% at 20Ԩ50% at 40Ԩ
90% at 20Ԩ
Max. altitude: 1000 m (a.s.l.) 1000 m (a.s.l.)
Table 1: Technical data
1.2 Protections
The panel is self-protected and protects the electropumps against:
overloads and excess temperature with automatic reset,
short circuits with fuses (only Plus model),
excess currents in pumps (overload protection),
abnormal voltages,
lack of phase and thermal protection KK,
dry operation,
rapid starts,
faults of the pressure sensor,
inconsistency of floats and/or probes,
blocking of the pumps.
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69
2 INSTALLATION
Strictly respect the electric supply values indicated on the electrical data plate.
Although it has a grade of protection IP55, it is not advisable to use it in an atmosphere charged with
oxidising or corrosive gases.
The panels must be protected against the direct rays of the sun and against unfavourable weather
conditions.
Use good quality cables with a section suitable for the current required by their motors and for their
length. Pay particular attention to the power cable which must carry the current for all the pipes
connected.
The sensors must be suitable for the place in which they are positioned.
It is necessary to take suitable steps to keep the temperature inside the panel within the “limits of
environment temperature use” listed below.
High temperatures can lead to accelerated ageing of all the components, resulting in more or less
severe malfunctions.
It is also recommended that the person carrying out installation should ensure the cable clamps are
watertight.
Accurately tighten the cable clamps where the power cable enters the panel and those of any
external controls, connected by the installer, so as to ensure that the cables cannot work loose from
the clamps.
2.1 Electrical connections
Ensure that the main switch on the power distribution panel is in OFF position (0) and that no one can switch on the
power accidentally before connecting the power cables to the terminals:
L1 - L2 - L3 - for three-phase systems
L - N - for single-phase systems
and to the isolating switch QS1.
Scrupulously observe all the regulations in force concerning safety and accident prevention.
Ensure that all the terminals are fully tightened, paying particular attention to the earth screw.
Connect the cables to the terminal board as indicated in the wiring diagrams.
Check that all the connecting cables are in excellent condition, with the external sheathing unbroken.
The system must be correctly and safely earthed as required by the regulations in force.
Check that the differential switch that protects the system is of the correct dimensions.
2.1.1 Instrumental checks to be carried out by the installer
Continuity of the protection leads and of the main and supplementary equipotential circuits.
Insulating resistance of the electric system between the active circuits L1-L2-L3 (short-circuited with each other)
and the equipotential protection circuit.
Testing the efficiency of the differential protection.
Testing the voltage applied between the active circuits L1-L2-L3 (short-circuited with each other) and the
equipotential protection circuit.
Testing operation.
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2.1.2 Boards and connections
Figure 1: E.box Basic Board
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71
Figure 2: E.Box Plus Board
Function
QS1 Supply line isolating switch (On the front panel of the e.box not shown in the figure)
L1 – L2 – L3 Three-phase power supply line connection
L – N Single-phase power supply line connection
Earthing connection
U - V - W Three-phase electrical connection of the pumps P1 and P2
L - N Single-phase electrical connection of the pumps P1 and P2
C - A - P Electrical connection for single-phase pumps P1 and P2 with external capacitor
C1 – C2 Electrical connection for external starting capacitor for single-phase pumps with
external capacitor. For P1 and P2. Basic version onl
y
.
A - P Electrical connection for external starting capacitor for single-phase pumps with
external capacitor. For P1 and P2. Plus version onl
y
.
KK1- KK2 Thermal protection input for the motor of pumps P1 and P2
A-B-C Terminals connecting digital inputs for level or pressure control
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72
R-N Terminals connecting digital alarm inputs
I: 11-12 Sensor input connection terminal
Q1: 14-15
Q2: 16-17
Q3: 18-19 Terminals connecting the alarms Q1, Q2, Q3.
FU2 - FU3 Panel protection fuses (Plus version only)
FU5 Pump P2 protection fuse (Plus version only)
FU4 Pump P1 protection fuse (Plus version only)
The supply voltage of the E.BOX PLUS panel must be the same as that of the pumps used. For
example, if the panel is fed with a supply voltage of 3~400V the pumps must be at 3~400V.
The E.BOX BASIC panel must be fed with a supply voltage of 1~230V. The pumps must be single-
phase 230V.
Connect the earth cables of the pumps to the earth terminals in the E.Box panel! Make sure that all
the cables have adequate dimensions for the currents they have to bear.
If the single-phase pump needs an external capacitor, it can be placed inside the panel.
If 2 pumps are used, they must be identical.
Attention, an incorrect electrical connection could damage the E.Box panel.
2.2 Electrical connection of the pumps
Connection of three-phase pumps
Figure 3: Electrical connection of pumps
Connection of single-phase pumps with internal capacitor.
The pumps must be connected to the terminals P1 and P2 shown in Figure 3. The neutral wire must be connected to
the terminal N, the phase wire must be connected to the terminal with a screenprinted L.
Connection of single-phase pumps with external capacitor.
Pumps with an external capacitor must be connected to the terminals P1 and P2 shown in Figure 5. Particular care
must be taken to respect the correspondence between the screenprinting and the names of the pump wires. The
pump cable marked C must be connected to terminal C. The same applies to cables A and P. See Figure 3.
The pump capacitor can be placed inside the E.box panel, on the metal bracket provided.
Three-phase pumps can be connected only to the E.box Plus. They must be connected to the terminals P1
and P2 as shown in Figure 3. The correct sequence of phases U, V and W must be respected so that they
turn in the correct direction.
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73
The capacitors must be connected as shown in Figure 4. Take care because in the E.Box Plus they share the same
terminal as the pump.
Figure 4: Connection of pump external capacitors
2.3 Power supply electrical connection
In the case of single-phase power supply use terminals L and N. In the case of three phase power supply use
terminals L1, L2, L3. See Figure 5 Electrical connection to the supply line.
Figure 5: Electrical connection to the supply line
Before starting work, disconnect the power from the supply line. Use cables with a suitable size for the
currents involved, considering that the in-line current is the total of the currents on the pumps.
Connect the earth cables of the pumps to the earth terminals in the E.Box panel!
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74
3 FRONT PANEL
Figure 6: Display label, present only on plus models
Figure 7: Front label
Section concerning the panel
White led indicating that the panel is fed
Red alarm led of the panel with the alarm reset button next to it. The number of blinks of the
led indicates the type of error, as shown in the table below.
List of panel alarms. The number of blinks of the led indicates the type of alarm. On the display
there is a complete indication of the problem. For further information, see the chapter PANEL
PROTECTIONS AND ALARMS.
Section concerning the pump
Green led, if lit it indicates that the pump is running.
Red alarm led of the pump with the alarm reset button next to it. The number of blinks of the
led indicates the type of error, as shown in the table on the label. On the display there is a
complete indication of the problem. For further information, see the chapter PANEL
PROTECTIONS AND ALARMS.
Leds indicating the type of pump operation: ON always on, OFF always off, AUTO the pump is
controlled by the panel.
Button for changing the pump operating mode. If held down for more than 3 seconds, it
switches on the pump until the button is released. Simply pressing the button alternates the
pump status from OFF to AUTO.
Pump to which the indications refer.
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4 PANEL INTERNAL REGULATING BOARD
To access the internal panel, slacken the screws, turn the cover of the electric panel downwards and operate the
commands.
Ref. Function
1 Warning lights for activating the digital inputs (N-A-B-C-R)
2 Trimmer for regulating the system (Imax – SP – DP).
3 Dip-switch for selecting functions (DS_A – DS_B).
4 Led indicating current overload set at the motor data plate values.
For a correct settin
g
the Led must be off.
4.1 Trimmer for regulating the system (Imax – SP – DP)
T1 – Trimmer (Imax)
Trimmer for setting the maximum current for the two electropumps P1 and P2 (0.25A –13A).
Set the Trimmer at the motor data plate value (the yellow led must be off).
T2 – Trimmer (SP – system Set Point) / Trimmer 3 (DP – Pressure level differential)
Trimmer for setting the pressures or level of the system.
The trimmer SP (set by DS_B5) presents a double regulating scale in bar: from 1 to 10 bar or from 7 to 15 bar
corresponding to the led lit, if a pressure sensor is used in the booster sets. This scale can also be expressed in
metres (as an optional version, using the plate provided): from 1 to 3 metres or from 2 to 5 metres
corresponding to the led lit, if an analog level sensor is used in the filling and draining sets.
The DP regulation is expressed as a percentage with respect to the value set in SP.
Before starting regulation, switch off the mains power.
1
2
33
22
4
Standard regulation in bars Optional regulation in metres
(plate supplied)
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76
4.2 Dip-switch for selecting functions (DS_A – DS_B)
1. N
o
.
ON OFF
1
STANDARD expansion
vessels, minimum 19
litres per pump.
Effective only in
pressure boosting and
kiwa
MAXI expansion
vessels, over 100
litres per pump.
Effective only in
pressure boosting
and kiwa
2 Automatic exchange
between pump P1 and
P2 every 24 hours.
Automatic exchange
between pump P1
and P2 at each start.
3
Checks too frequent
starts and reduces them
to 8 per minute per
pump.
Allows all the starts
requested by the
system.
4
Dry operation protection
active. Pressure
boosting only. Indicates
dry operation if the
pressure falls below
0.5bar.
Dry operation
protection not active.
5
Activates KIWA
operating mode if
pressure boosting is
active.
Does not activate
KIWA mode.
6 KIWA mode switch-off
delay of 2 seconds. KIWA mode switch-
off delay of 4
seconds.
7 (**) Pump P1 not available. Pump P1 available.
8 (**) Pump P2 not available. Pump P2 available.
2. N
o
.
ON status OFF status
1 (*) Operation as pressure
boosting set.
OFF
2 (*) Operation as filling set. OFF
3 (*) Operation as draining
set. OFF
4 Use of electric probes. Use of floats.
5 Pressure set point
scale:
7-16 bar / 2-5 m.
Pressure set point
scale:
1-10 bar / 0-3 m.
6 Not used Not used
7 (**) Regulation with analog
sensor with current
output. OFF
8 (**) Regulation with analog
sensor with voltage
output. OFF
(*) Only one (and at least one) of these Dip Switches can be in ON position.
(**) Only one (or none) of these Dip Switches can be in ON position.
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77
5 PRESSURE BOOSTING FUNCTION
The E.box panel can be used for making a system to increase water pressure. As control inputs, either pressure
switches on a pressure sensor can be used. To operate, the panel requires an expansion vessel.
5.1 Expansion vessel
In pressure boosting it is necessary to use an expansion vessel of at least 19 litres per pump.
5.2 Electrical connections of pump and supply
Connect the supply line and the pumps as described in the chapter ELECTRICAL CONNECTIONS.
5.3 Connection of additional protections: high pressure, low pressure and motor thermal
protection
It is possible, but not necessary, to use the alarm inputs to the E.box so that the pumps stop in the case of pressure
that is too high, too low, or too high motor temperature. In the case of an alarm, the pumps stop, the alarm leds blink,
the corresponding alarm outputs are activated. If the display is present, the type of alarm is indicated. When the alarm
conditions no longer exist, the E.box resumes normal operation.
Alarm, Pressure in system too high: the pressure switch must be installed in the delivery of the set. The
normally closed contact of the pressure switch must be connected to terminal R of the E.box. The pressure
switch must be set at the maximum pressure that can be reached by the system. If it is not used, the contact
is jumpered.
Alarm, Pressure in system too low: the pressure switch can be installed either on suction or on delivery
depending on the type of system. The pressure switch must be connected to terminal N of the E.box, it must
be set at the minimum pressure necessary for the system to work correctly. The contact must open if the
pressure falls below the minimum value. This contact may be used either to prevent blocks for lack of water or
to discover burst pipes. A level probe or float can also be connected to this alarm to check the state of a tank
or well. If it is not used, the contact is jumpered.
Figure 8: Inputs and outputs
Motor thermal protection: the device has an input for the thermal protection of each motor. If the motor used
is provided with thermal protection, this protection can be connected to the terminals KK shown in Figure 9. If
there is no protection in the motor, the terminals must be jumpered.
If the alarms are not used, the corresponding inputs must be jumpered. So jumpers must be fitted on the inputs of the
contacts N, R, KK1 and KK2. These jumpers are provided with the E-box.
ENGLISH
78
Figure 9: Thermal protection inputs KK
5.4 Connection of the alarm outputs
If alarms occur, this is indicated by the E.box in three ways:
With the leds on the front panel, which give a number of blinks depending on the error.
With the outputs Q1, Q2, Q3 which short circuit as specified in Table 17. The operating logic of the
alarms is as follows: Q1 closes following malfunctions of pump 1, Q2 of pump 2 and Q3 for general
errors.
With the indications on the display (if present). In this case it is also possible to see the alarm log.
If the panel is not fed, Q1, Q2 and Q3 are closed, so they give an alarm signal.
5.5 Operation with pressure sensor (recommended choice)
It is recommended to use this operating mode, rather than pressure switches, because it allows greater flexibility in
managing the system, the pressure distributed by the set can be seen, and installation is easier. In this case it will be
possible to set the Set Point pressure and the pressure differential for the restarting and stopping of the pumps.
5.6 Connection of the pressure sensor
The pressure sensor must be connected to the terminal board, see Figure 10 Pressure sensor connection, according
to the following diagram:
Figure 10: Pressure sensor connection 4..20Ma
5.7 Operation with pressure switches
If you decide to operate the booster set with pressure switches, they must be connected on the delivery of the booster
set. The pressure switches to be used are B and C and they are connected as indicated in the next chapter.
Connection of pressure switches
The pressure switches must be connected to the contacts B and C of the terminal board shown in Figure 11.
Pressure sensor connections
4..20mA
Terminal Cable to be connected
11 - OUT/GND (brown)
12 +VCC (white)
ENGLISH
79
Figure 11: Terminals for connecting the pressure switches
5.8 Setting with the display, wizard
The E.box D can be configured with a simple wizard. The device asks the user for all the parameters necessary for its
configuration. If necessary, it can be loaded by pressing the “set” + “+” keys when switching on. To navigate in the
wizard, use the following keys:
“mode” to accept the parameter displayed and move on to the next
“mode” held down for more than 1 second to return to choose the parameter
“-“ and “+” to vary the value of the parameter.
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