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
1GENERAL ................................................................................................................................................68
1.1Technical characteristics................................................................................................................68
1.2Protections.......................................................................................................................................68
2INSTALLATION........................................................................................................................................69
2.1Electrical connections.....................................................................................................................69
2.1.1 Instrumental checks to be carried out by the installer ...................................................................69
2.1.2 Boards and connections.................................................................................................................70
2.2Electrical 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
2.3Power supply electrical connection ..............................................................................................73
3FRONT PANEL ........................................................................................................................................74
4PANEL INTERNAL REGULATING BOARD ...........................................................................................75
4.1Trimmer for regulating the system (Imax – SP – DP)...................................................................75
4.2Dip-switch for selecting functions (DS_A – DS_B)......................................................................76
5PRESSURE BOOSTING FUNCTION......................................................................................................77
5.1Expansion vessel.............................................................................................................................77
5.2Electrical connections of pump and supply.................................................................................77
5.3Connection of additional protections: high pressure, low pressure and motor thermal
protection....................................................................................................................................................77
5.4Connection of the alarm outputs ...................................................................................................78
5.5Operation with pressure sensor (recommended choice)............................................................78
5.6Connection of the pressure sensor...............................................................................................78
5.7Operation with pressure switches.................................................................................................78
5.8Setting with the display, wizard.....................................................................................................79
5.9Setting with a pressure sensor......................................................................................................80
5.10Configuration with pressure switches ..........................................................................................81
5.11Setting the E.box with dip switches ..............................................................................................81
5.12Activation of the set ........................................................................................................................82
5.13Regulating the rated current of the pumps (Imax), Set point (SP) and differential restarting
pressure (DP)..............................................................................................................................................82
5.14System operation.............................................................................................................................83
Pressure switches:....................................................................................................................................83
Pressure sensor:.......................................................................................................................................83
6FILLING FUNCTION ................................................................................................................................84
6.1Electrical connections of pump and supply.................................................................................84
6.2Control inputs ..................................................................................................................................84
6.3Connection of additional protections: overflow, water lack, motor thermal protection..........84
6.4Connection of the alarm outputs ...................................................................................................86
6.5Connection of floats or level probes.............................................................................................86
6.6Depth sensor connection ...............................................................................................................86
6.7Setting with the display, wizard.....................................................................................................87
6.8Configuration of floats or level probes .........................................................................................87
6.9Configuration with a depth sensor................................................................................................88
6.10Setting the E.box with dip switches ..............................................................................................89
6.11Activation of the set ........................................................................................................................89
6.12Regulating the rated current of the pumps (Imax) and the pump starting and stopping
levels (only with depth sensor connected)..............................................................................................89
6.13System 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
7Draining function....................................................................................................................................92
7.1Electrical connections of pump and supply.................................................................................92
7.2Control inputs ..................................................................................................................................92

ENGLISH
63
7.3Connection of additional protections: overflow, water lack, motor thermal protection..........92
7.4Connection of the alarm outputs ...................................................................................................94
7.5Connection of floats or level probes.............................................................................................94
7.6Depth sensor connection ...............................................................................................................94
7.7Setting with the display, wizard.....................................................................................................95
7.8Configuration of floats or level probes .........................................................................................95
7.9Configuration with a depth sensor................................................................................................96
7.10Setting the E.box with dip switches ..............................................................................................97
7.11Activation of the set ........................................................................................................................97
7.12Regulating the rated current of the pumps (Imax) and the pump starting and stopping
levels (only with depth sensor connected)..............................................................................................98
7.13System 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
8KIWA PRESSURE BOOSTING FUNCTION..........................................................................................100
8.1Expansion vessel...........................................................................................................................100
8.2Electrical connections of pump and supply...............................................................................100
8.3Connection of additional protections: high pressure and motor thermal protection............100
8.4Connection of the alarm outputs .................................................................................................101
8.5Operation with pressure sensor (recommended choice)..........................................................101
8.6Connection of the pressure sensor.............................................................................................101
8.7Operation with pressure switches...............................................................................................101
8.8Connection of pressure switches................................................................................................101
8.9Connecting the low-pressure pressure switch ..........................................................................102
8.10Setting with the display, wizard...................................................................................................102
8.11Setting with a pressure sensor:...................................................................................................103
8.12Configuration with pressure switches:.......................................................................................103
8.13System status in Kiwa mode........................................................................................................104
8.14Setting the E.box with dip switches ............................................................................................104
8.15Activation of the set ......................................................................................................................104
8.16Regulating the rated current of the pumps (Imax), Set point (SP) and differential restarting
pressure (DP)............................................................................................................................................105
8.17System operation...........................................................................................................................105
Pressure switches:..................................................................................................................................105
Pressure sensor:.....................................................................................................................................105
9THE KEYPAD AND THE DISPLAY.......................................................................................................107
9.1Status line.......................................................................................................................................108
9.2Menus .............................................................................................................................................108
9.3Access to the menus.....................................................................................................................108
Direct access with a combination of keys...............................................................................................108
Access by name with a drop-down menu...............................................................................................110
9.4MEANING 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

ENGLISH
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
10PANEL PROTECTIONS AND ALARMS ...............................................................................................114
10.1Errors indicated by alarm leds and relays..................................................................................114
10.2Digital 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
10.3Alarms 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

ENGLISH
65
- 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
11RESET AND FACTORY SETTINGS......................................................................................................122
11.1General system reset ....................................................................................................................122
11.2Restoring 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

ENGLISH
66
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

ENGLISH
67
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

ENGLISH
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.

ENGLISH
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.