DAB Evosta2 11/139 SAN V Operating and maintenance manual

INSTRUCTIONS FOR INSTALLATION AND MAINTENANCE
EVOSTA2
EVOSTA3

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INDEX
1. KEY .......................................................................................................................................................... 30
2. GENERAL ................................................................................................................................................ 30
2.1 Safety................................................................................................................................................ 30
2.2 Responsibility.................................................................................................................................. 30
2.3 Particular warnings......................................................................................................................... 30
3. PRODUCT DESCRIPTION ...................................................................................................................... 31
4. PUMPED LIQUIDS................................................................................................................................... 31
5. APPLICATIONS....................................................................................................................................... 32
6. TECHNICAL DATA.................................................................................................................................. 32
7. MANAGEMENT ....................................................................................................................................... 33
7.1 Storage............................................................................................................................................. 33
7.2 Transport.......................................................................................................................................... 33
7.3 Weight .............................................................................................................................................. 33
8. INSTALLATION ....................................................................................................................................... 33
8.1 Mechanical installation................................................................................................................... 34
8.2 User Interface Position................................................................................................................... 34
8.3 Rotation of the user interface ........................................................................................................ 36
8.4 Non-return valve.............................................................................................................................. 37
8.5 Insulating the pump body (only for Evosta3)............................................................................... 37
9. ELECTRICAL CONNECTIONS............................................................................................................... 38
9.1 Power supply connection............................................................................................................... 38
10. START...................................................................................................................................................... 40
10.1 Degassing the pump....................................................................................................................... 41
10.2 Automatic Degassing ..................................................................................................................... 41
11. FUNCTIONS............................................................................................................................................. 42
11.1 Regulating Modes ........................................................................................................................... 42
11.1.1 Regulation with Proportional Differential Pressure .................................................................... 42
11.1.2 Regulation with Constant Differential Pressure ......................................................................... 43
11.1.3 Regulation with constant curve.................................................................................................. 43
12. CONTROL PANEL................................................................................................................................... 44
12.1 Elements on the Display................................................................................................................. 44
12.2 Graphic Display............................................................................................................................... 44
13. FACTORY SETTINGS ............................................................................................................................. 47
14. TYPES OF ALARM.................................................................................................................................. 47
15. MAINTENANCE....................................................................................................................................... 47
16. DISPOSAL ............................................................................................................................................... 47
17. DIMENSIONs ........................................................................................................................................... 48
18. PERFORMANCE CURVES ..................................................................................................................... 50
INDEX OF FIGURES
Figure 1: Pumped liquids, warnings and operating conditions........................................................................ 31
Figure 2: Mounting EVOSTA2 or EVOSTA3................................................................................................... 34
Figure 3: Assembly position ............................................................................................................................ 34
Figure 4: Positions of the user interface.......................................................................................................... 35
Figure 5: Positions of the user interface.......................................................................................................... 36
Figure 6: Changing the position of the user interface...................................................................................... 36
Figure 7: Insulating the pump body ................................................................................................................. 37
Figure 8: Venting of the pump ......................................................................................................................... 41
Figure 9: Automatic venting of the pump......................................................................................................... 41
Figure 10: Display............................................................................................................................................ 44
Figura 11: Evosta3 Display.............................................................................................................................. 45

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INDEX OF TABLES
Table 1: Functions ........................................................................................................................................... 31
Table 2: Technical data ................................................................................................................................... 32
Table 3: Maximum head (Hmax) and maximum flow rate (Qmax) of EVOSTA2, EVOSTA3 circulators........ 33
Table 4: Mounting the Evosta3 connector....................................................................................................... 39
Table 5: Mounting the Evosta2 connector....................................................................................................... 40
Table 6: Pump operating modes ..................................................................................................................... 46
Table 7: Types of Alarm................................................................................................................................... 47

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1. KEY
The frontispiece shows the version of this document in the form Vn.x. This version indicates that the document
is valid for all software versions of the device n.y. For example: V3.0 is valid for all Sw: 3.y.
In this document the following symbols will be used to avoid situations of ranger:
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.
2. GENERAL
Read this documentation carefully before installation.
Skilled personnel: Installation must 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. (Definition for technical personnel IEC 364).
The appliance may not be used by children under 8 years old or by persons with reduced physical, sensory or
mental capacities, or who lack experience or knowledge, unless they are under supervision or after they have
received instructions concerning the safe use of the appliance and the understanding of the dangers involved.
Children must not play with the appliance.
Ensure that the product has not suffered any damage during transport or storage.
Check that the outer casing is unbroken and in excellent conditions.
2.1 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.
2.2 Responsibility
The Manufacturer does not vouch for correct operation of the machine or answer for any damage that it
may cause if it has been tampered with, modified and/or run outside the recommended work range or in
contrast with other indications given in this manual.
2.3 Particular warnings
Always switch off the mains power supply before working on the electrical or
mechanical part of the system. Wait for the warning lights on the control panel to go
out before opening the appliance. The capacitor of the direct current intermediate
circuit remains charged with dangerously high voltage even after the mains power has
been turned off.
Only firmly cabled mains connections are admissible. The appliance must be earthed
(IEC 536 class 1, NEC and other applicable standards).

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Mains terminals and motor terminals may still have dangerous voltage when the motor
is stopped.
If the power cable is damaged, it must be replaced by the technical assistance service
or by qualified personnel, so as to avoid any risk.
3. PRODUCT DESCRIPTION
Figure 1: Pumped liquids, warnings and operating conditions
The circulators in the EVOSTA2 and EVOSTA3 series represent a complete range of circulators.
These installation and operating instructions describe EVOSTA2 and EVOSTA3 models. The type of model is
indicated on the pack and on the identification plate.
The table below shows the EVOSTA2 and EVOSTA3 models with built-in functions and features.
Functions/features
EVOSTA 2
EVOSTA 3
Proportional pressure
●
●
Constant pressure
●
●
Constant curve
●
●
Dry-running protection
●
Automatic degassing
●
Table 1: Functions
4. PUMPED LIQUIDS
Clean, free from solids and mineral oils, not viscous, chemically neutral, close to the properties of water (max.
glycol contents 30%)

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5. APPLICATIONS
EVOSTA2, EVOSTA3 series circulators allow integrated adjustment of the differential pressure which enables
the circulator performance to be adapted to the actual requirements of the system. This determines
considerable energy saving, a greater possibility of control of the system, and reduced noise.
EVOSTA2, EVOSTA3 circulators are designed for the circulation of:
–water in heating and conditioning systems.
–water in industrial water circuits.
–domestic water only for the versions with bronze pump body.
EVOSTA2, EVOSTA3 circulators are self-protected against:
–Overloads
–Lack of phase
–Excess temperature
–Over-voltage and under-voltage
6. TECHNICAL DATA
Supply voltage
1x230 V(+/-10%), 50/60 Hz
Absorbed power
See electrical data plate
Maximum current
See electrical data plate
Grade of protection
IPX5
Protection class
F
TF Class
TF 110
Motor protector
No external motor protector is needed
Maximum environment temperature
40 ºC
Liquid temperature
-10 ºC ÷ 110 ºC
Flow rate
See Table 3
Head
See Table 3
Maximum working pressure
1.0 Mpa – 10 bar
Minimum working pressure
0.1 Mpa – 1 bar
Lpa [dB(A)]
≤ 43
Table 2: Technical data
Designation index
(example)
EVOSTA
40-70/
130
½”
X
Series name
Maximum head range (dm)
Centre distance (mm)
½” = 1”½ threaded outlets
= 1” threaded outlets
Standard (no ref.) = 1½” threaded outlets
½” = 1” threaded outlets
X = bocche filettate da 2”

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EVOSTA2, EVOSTA3 Hmax [m] Qmax [m3/h]
EVOSTA2 40-70/xxx M230/50-60 6,9 3,6
EVOSTA2 80/xxx M230/50-60 8 4,2
EVOSTA3 40/xxxM230/50-60 4 2,9
EVOSTA3 60/xxx M230/50-60 6 3,6
EVOSTA3 80/xxx M230/50-60 8 4,2
Table 3: Maximum head (Hmax) and maximum flow rate (Qmax) of EVOSTA2, EVOSTA3 circulators
7. MANAGEMENT
7.1 Storage
All the circulators must be stored in a dry covered place, with possibly constant air humidity, free from vibrations
and dust. They are supplied in their original pack in which they must remain until the time of installation. If this
is not the case, accurately close the suction and delivery mouth.
7.2 Transport
Avoid subjecting the products to needless impacts and collisions. To lift and transport the circulator use lifting
devices with the aid of the pallet supplied with it (if contemplated).
7.3 Weight
The adhesive plate on the packaging indicates the total weight of the circulator.
8. INSTALLATION
Carefully follow the advice in this chapter to carry out correct electrical, hydraulic and mechanical installation.
Always switch off the mains power supply before working on the electrical or
mechanical part of the system. Wait for the warning lights on the control panel to go
out before opening the appliance. The capacitor of the direct current intermediate
circuit remains charged with dangerously high voltage even after the mains power has
been turned off.
Only firmly cabled mains connections are admissible. The appliance must be earthed
(IEC 536 class 1, NEC and other applicable standards).
Ensure that the voltage and frequency on the data plate of the EVOSTA2, EVOSTA3
circulator are the same as those of the power mains.

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8.1 Mechanical installation
Figure 2: Mounting EVOSTA2 or EVOSTA3
The arrows on the pump housing indicate the flow direction through the pump. See fig. 1, pos. A.
1. Fit the two gaskets when you mount the pump in the pipe. See fig. 1, pos. B.
2. Install the pump with a horizontal motor shaft. See fig. 1, pos. C.
3. Tighten the fittings.
8.2 User Interface Position
Always install the EVOSTA2, EVOSTA3 circulator with the motor shaft in a horizontal
position.
Install the electronic control device in a vertical position.
Figure 3: Assembly position
−The circulator may be installed in heating and conditioning systems on either the delivery pipe or the return
pipe; the arrow marked on the pump body indicates the direction of flow.
−Install the circulator as far as possible above the minimum boiler level and as far as possible from bends,
elbows and junction boxes.
A
B
C

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−To facilitate control and maintenance operations, install an interception valve both on the suction pipe and
on the delivery pipe.
−Before installing the circulator, accurately flush the system with only water at 80°C. Then drain the system
completely to eliminate any harmful substance that may have got into circulation.
−Avoid mixing additives derived from hydrocarbons and aromatic products with the circulating water. It is
recommended that the addition of antifreeze, where necessary, should not exceed 30%.
−In the event of heat insulation use the special kit (if provided) and ensure that the condensate draining
holes in the motor casing are not closed or partly blocked.
−In the case of maintenance, always use a set of new gaskets.
Never insulate the electronic control device.
8.2.1 Positioning of the user interface in heating and domestic hot water systems
It is possible to position the user interface with the cable facing to the left, to the right, or downwards.
Figure 4: Positions of the user interface

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8.2.2 Positioning of the user interface in conditioning and cold water systems
The user interface can be positioned only with the cable facing downwards.
Figure 5: Positions of the user interface
8.3 Rotation of the user interface
If the circulator is installed on pipes in a horizontal position, it will be necessary to rotate the interface with the
respective electronic device through 90 degrees in order to maintain the grade of IP protection and to allow
the user a more convenient interaction with the graphic interface.
Before rotating the circulator, ensure that it has been completely drained.
To rotate the EVOSTA2, EVOSTA3 circulator, proceed as follows:
1. Remove the 4 fixing screws of the circulator head.
2. Rotate the motor casing with the electronic control device through 90 degrees clockwise or
counterclockwise, as necessary.
3. Reassemble and tighten the 4 screws that fix the circulator head.
The electronic control device must always remain in vertical position!
Figure 6: Changing the position of the user interface

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ATTENTION
Water at high temperature.
High temperature.
ATTENTION
System under pressure
- Before dismantling the pump, empty the system or close the interception valves on
both sides of the pump. The pumped liquid may be at a very high temperature and
high pressure.
8.4 Non-return valve
If the system is equipped with a non-return valve, ensure that the minimum pressure of the circulator is always
higher than the valve closing pressure.
8.5 Insulating the pump body (only for Evosta3)
Figure 7: Insulating the pump body
It is possible to reduce the loss of heat from the EVOSTA3 pump by insulating the pump body with the
insulating shells supplied with the pump. See fig.9
Do not insulate the electronic box and do not cover the control panel

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9. ELECTRICAL CONNECTIONS
The electrical connections must be made by expert, qualified personnel.
ATTENTION! ALWAYS RESPECT THE LOCAL SAFETY REGULATIONS.
Always switch off the mains power supply before working on the electrical or
mechanical part of the system. Wait for the warning lights on the control panel to go
out before opening the appliance. The capacitor of the direct current intermediate
circuit remains charged with dangerously high voltage even after the mains power has
been turned off.
Only firmly cabled mains connections are admissible. The appliance must be earthed
(IEC 536 class 1, NEC and other applicable standards).
THE SYSTEM MUST BE CORRECTLY AND SAFELY EARTHED!
It is advised to install a correctly dimensioned differential switch to protect the system,
type: class A with adjustable leakage current, selective.
The automatic differential switch must be marked with the following symbols:
–The circulator does not require any external motor protection.
–Ensure that the supply voltage and frequency are the same as the values indicated on the electrical
data plate of the circulator.
9.1 Power supply connection
Before supplying power to the circulator, ensure that the cover of the EVOSTA2, EVOSTA3 control
panel is perfectly closed!

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EVOSTA3
Phase
1
2
3
Action
Unscrew the cable gland nut
and extract the terminal board
from the connector, releasing it
from the side clips.
Rotate the terminal board
through 180°.
Fit nut and connector on the
cable. Strip the wires as
indicated in the figure.
Connect the wires to the
terminal board, respecting
the phase, neutral and earth
Illustratio
n
Phase
4
5
Action
Insert the wired terminal board
in the cable gland, securing it
with the side clips. Screw on
the locking nut.
Connect the wired
connector to the pump,
securing it with the rear
hook.
Illustratio
n
Table 4: Mounting the Evosta3 connector

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EVOSTA2
Phase
1
2
3
Action
Unscrew the cable gland
nut and extract the terminal
board from the connector.
Remove the retaining screw.
Fit nut and connector on the
cable. Strip the wires as
indicated in the figure. Connect
the wires to the terminal board,
respecting the phase, neutral
and earth.
Illustration
Phase
4
5
Action
Insert the wired terminal
board in the cable gland.
Screw on the locking nut.
Connect the wired connector
to the pump and tighten the
retaining screw.
Illustration
Table 5: Mounting the Evosta2 connector
10. START
All the starting operations must be performed with the cover of the EVOSTA2,
EVOSTA3 control panel closed.
Start the system only when all the electrical and hydraulic connections have been
completed.
Avoid running the circulator when there is no water in the system.
As well as being at a high temperature and pressure, the fluid in the system may also
be in the form of steam. DANGER OF SCALDING!
It is dangerous to touch the circulator. DANGER OF SCALDING!

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Once all the electrical and hydraulic connections have been made, fill the system with water and if necessary
with glycol (for the maximum glycol percentage see par. 3) and feed the system.
Once the system has been started it is possible to modify the operating modes to adapt better to the plant
requirements (see par.12).
10.1 Degassing the pump
Figure 8: Venting of the pump
Always vent the pump before starting!
The pump must never run when dry.
10.2 Automatic Degassing
Automatic degassing occurs only for the Evosta3 pump. Hold down the Mode key for 3" and the function
starts: 1 minute at maximum speed, then it passes to the set mode.
Figure 9: Automatic venting of the pump

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11. FUNCTIONS
11.1 Regulating Modes
EVOSTA2, EVOSTA3 circulators allow the following regulating modes depending on plant requirements:
−Proportional differential pressure regulation depending on the flow present in the plant.
−Constant differential pressure regulation.
−Regulation with constant curve.
The regulating mode may be set through the EVOSTA2, EVOSTA3 control panel.
11.1.1 Regulation with Proportional Differential Pressure
In this regulating mode the differential pressure is
red
uced or increased as the demand for water
decreases or increases.
The Hs set point may be set from the display.
Regulation indicated for:
–Heating and conditioning plants with high
load losses
–Plants with secondary differential pressure
regulator
–Primary circuits with high load losses
–Domestic water recirculating systems with
thermostatic valves on the rising columns
11.1.1.1 Regulation with Proportional Differential Pressure –Advanced Menu
Holding down the Mode key for 20" gives access to
the Advanced Menu with the possibility of selecting
from 6 curves with proportional differential pressure
1
2
3
4
5
6

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11.1.2 Regulation with Constant Differential Pressure
In this regulating mode the differential pressure is
kept constant, irrespective of the demand for water,
The Hs set point may be set from the display.
Regulation indicated for:
–
Heating and conditioning plants with low
load losses
–Single-
pipe systems with thermostatic
valves
–Plants with natural circulation
–Primary circuits with low load losses
–Domestic water recirculating systems with
thermostatic valves on the rising columns
11.1.3 Regulation with constant curve
In this regulating mode the circulator works on
characteristic curves at a constant speed.
Regulation indicated for heating
and conditioning
plants with constant flow.

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12. CONTROL PANEL
The functions of EVOSTA2, EVOSTA3 circulators can be modified by means of the control panel on the cover
of the electronic control device.
12.1 Elements on the Display
Figure 10: Display
1
Luminous segments indicating the type of set curve
2
Display showing the instantaneous power absorption in Watt, the flow rate in m3/h, the head in metres
and the set curve.
3
Key for selecting the pump setting
4
Luminous segments indicating the set curve
12.2 Graphic Display
12.2.1 Luminous segments indicating the pump setting
The pump presents nine setting options that can be selected with the key.
The pump settings are indicated by six luminous segments on the display.
12.2.2 Key for selecting the pump setting
Whenever the key is pressed, the pump setting is changed. A cycle consists of pressing the key ten
times.

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12.2.3 Display Operation
Figura 11: Evosta3 Display
The Evosta3 circulator has a display that is able to show the following values.
Height of the selected curve (1-2-3)
Instantaneous power absorption in Watt
Instantaneous head in m
Instantaneous flow rate in m3/h
The values are shown in sequence for 3". Once the viewing cycle is ended, the display switches off and only
the operating mode LED remains lit.
If the selection key is pressed within 10", the display performs 6 viewing cycles, then goes into stand-by.
If the key is pressed again within 10", the display performs 11 more viewing cycles to allow a greater reading
time.