GOK SmartBox 1 User manual

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Article No. 28 100-
Version 12.2007
Page 1 of 12
SmartBox 1 / SmartBox 2 / SmartBox 3
Electronic Content Indicator - Optionally with additional functions
CONTENT Page:
GENERAL 1
DESIGN 1
OPERATING MEDIA 1
IDENTIFICATION 2
INSTALLATION 2
START-UP 5
EXAMPLES FOR PROGRAMMING 6
OPERATION 10
PERFORMANCE CHECK 10
MAINTENANCE 10
REPAIR 10
ADDITIONAL TECHNICAL DATA 11
LIST OF ACCESSORIES 11
GENERAL
The electronic tank management system SmartBox 1, SmartBox 2 and SmartBox 3 can be used
for monitoring of the liquids contained in unpressurized liquids tanks.
In addition to the registration of tank content, other functions can be implemented by system
enhancements, e.g. temperature measurement, data telecommunication, or connection to master
control systems of the building.
The SmartBox 2 has additional relay control functions, e.g. for activating external alarm devices,
solenoid valves, or the dry-run protection function of pumps.
The SmartBox 3 has relay control functions and an audible alarm for minimum level Indication.
When the acoustic alarm sounds, it can be switched off by pressing the ‘Quit’ key.
Thanks to its modular design, the system can be equipped with additional modules, e.g. with an
analog interface or a GSM module for telecommunication.
The indicated measurements are not gaged for invoicing.
The measuring probe is not a safety device, not even in connection with an electronic indicator.
Accordingly, it will not replace a limit monitoring indicator at the tank.
To operate the device as intended and to observe the warranty conditions, it is imperative that
you adhere to this Installation and Operating Manual and hand it over to the user.
DESIGN
The SmartBox 1 has an 8-digit LCD display and a measuring input for connecting the probe. The
SmartBox 2 has additionally 2 programmable relays with make and break switching output. The
SmartBox 3 has a programmable relay with make and break switching output and an acoustic
alarm for minimum level Indication. As a standard, the measuring probe can be installed with tank
connecting thread G1, G1½ or G2.
OPERATING MEDIA
Fuel oil EL acc. to DIN 51603-1 petroleum fire point > 55°C
Diesel fuel DK acc. to DIN EN 590 alcohol fire point > 55°C
FAME (Biodiesel) acc. to DIN EN 14214 glycerin
Hydraulic oil glycol
Motor oil brake fluid
Vegetable oil water
Urea solution
e.g. AdBlue acc. to
DIN 70700
Otto fuel
with fire point < 55°C
only with SmartBox
in EX version

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Article No. 28 100-
Version 12.2007
Page 2 of 12
IDENTIFICATION
Label Explanation
Pursuant to EN 50081-1, EN 50082-1 and EN 61010-1 / A2
INSTALLATION
Check the indicator and the probe element for transport damages before start of the installation.
Indicator and measuring probe must only be installed and commissioned by qualified personnel.
This requirement also applies to maintenance and repairs. In case of improper installation, any
warranty claims will be forfeited.
•The device must only be installed into tanks which are not operated under pressure. This is to
say that the tanks must be equipped with a tank ventilation according to the regulations.
Additionally, heating oil and fuel tanks must have a functioning limit monitoring indicator as
overfill protection.
•The inlet of the probe cable at the tank must be sealed in such a way that no smell will permeate
or water will penetrate under operating conditions.
Notes on installation
Expert installation under observation of the technical regulations for planning, construction and
operation of the system as a whole is the precondition for faultless functioning of the contents
indicator. These regulations also include the accident prevention regulations of the employers’
liability insurance associations, the VDE regulations, and the installation and operating instructions
for the fluid tank. The housing of the indicator is suitable for wall mounting and is connected to the
230 V mains supply. Under normal circumstances, the indicator must be operated with the
housing cover closed. It is installed and commissioned by the qualified technician while the unit is
open.
➨Warning: Keep away from the area of the 230V terminal.
Installation of the indicator
Mount the indicator to the wall in a suitable position. After loosening the four screws, open the
indicator by removing the cover. Mount the unit to a smooth vertical wall by means of four dowels.
Mount the housing of the indicator by the four fixing holes by means of the enclosed screws.
Take care not to damage the housing! After connecting the terminals and setting the unit up,
rescrew the cover.
The indicator must not be installed in areas subject to explosion hazards!
Installation of the probe element
•For welded basement steel tanks and buried tanks, the probe is installed by
means of the enclosed screw fitting with cable bushing.
•In most cases of installation to basement tanks, the fuel gauge with float used
before is dismounted so that its opening can be used to screw in the probe unit.
•With buried tanks, there usually is a free opening to screw in the probe element;
it will be closed with a removable filler plug.
Installation of the probe into the tank by means of the enclosed screw fitting (see
illustration on the right):
•If applicable, switch the oil burner off and lock the take-off pipe of the tank.
•Clear the opening at the tank.
•Push the screw fitting, if applicable with reduction bush(es), over the probe
cable and insert the probe into the tank.
•Seal the screw fitting smell-tight (e.g. with PTFE tape) and screw it into the tank
cover.
•Lower the probe into the tank until the probe head touches the tank floor (you
will feel that through the cable). Then, screw down the cable gland to fix the
cable. Optionally, the probe can also be fixed in a lying position on the tank
floor.
•Usually, it is not necessary to perform a probe zero adjustment (step 9.Offset calibration).

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Article No. 28 100-
Version 12.2007
Page 3 of 12
Re-open the take-off line of the tank and reactivate the oil burner if applicable. Check the function
of the oil burner.
Electrical Installation Indicator without cover lid
Connection probe cable
1 + = red
2 - = black
Connection line between indicator and probe unit:
Voltage: Probe element 20 V DC
Connection: Probe connection cable to terminals
1 + 2 (see Fig. on the right)
Air capillaries: The cable must be installed in such a
way that pressure equalization with the
ambient air is ensured but no moisture
can penetrate into the cable end.
Extension: The probe cable can be extended by
max. 200 m - e.g. with cable type NYM
or YR (moisture-proof) or NYY
(ground) and with min. cable cross-
section 2 x 0.4 mm2. For cable
extension in the dome or outdoors, a
watertight connection socket with
special pressure equalization filter
must be used (accessory).
Shield: If the probe cable (or extension) runs
close to power lines, a shielded signal
line should be used (connect shield to
PE terminal).
Connection of supply voltage:
Voltage: 230 V AC 50 Hz
Connection: Terminals PE, N + L to the indicator
(cable not comprised in the delivery )
Connection of the relay contacts at the indicator SmartBox 2 und SmartBox 3
The indicator SmartBox 2 has two relay contact pairs (SmartBox 3 ➜one) for the connection of
external control circuits or for activating external alarm or signal devices.
In case of failure of the unit and if the fill level (and optionally the temperature) is above the
selected limit, the contact of relay terminals 6 + 7 and 9 + 10 are closed, or 5 + 6 and 8 + 9 are
open - see the legend on the PCB in the unit.
Switching
voltage max. 250 V AC
Switching current max. 3.5 A
Connection closed in case of alarm open in case of alarm
Relay 1 terminals 5 + 6 terminals 6 + 7 only SmartBox 2
Relay 2 terminals 8 + 9 terminals 9 + 10 SmartBox 2 + 3
Connection of interface to SmartBox 4, SmartBox 5 or PC set
The measured values can be transmitted to the SmartBox 4, SmartBox 5 or the PC set via the in-
tegrated interface “SERIAL LINK OUTPUT” terminals 3 + 4.
MINUS PLUS
ENTER
Probe
SENSOR

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Article No. 28 100-
Version 12.2007
Page 4 of 12
Fuel oil tank - wiring example Smart Box1
Rain water reservoir - wiring example SmartBox 2
SmartBox 1
SmartBox 2
MINUS PLUS
ENTER
MINUS PLUS
ENTER
measuring probe
oil tank
measuring
Relay 1: 6
-
7 =
break contact
=> pump safe to run dry
solenoid valve
for backfeed
feed pump
water for
domestic use
drinking water
network
optional
switch
storm
water
reservoir
Relay 2: 8
-
9 =
make contact
=> automatic backfeed
control system
probe

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Article No. 28 100-
Version 12.2007
Page 5 of 12
START-UP
After the contents indicator has been installed, it can be started up.
Before programming, you need to ascertain the tank data and enter the values into the right
column Input value of the following table. Then, enter the values for the individual entry steps.
Optionally, the device can also be programmed as explained in the enclosed Quick Guide.
Setting a parameter:
Press ENTER to call the setup mode.
Select the desired setting parameter via PLUS.
Press ENTER to call up the value selection for the parameter.
Set the value with PLUS/MINUS, press ENTER to save.
Quitting the setup
mode:
You can quit the setup mode at any time.
Select “8.Exit“ and press ENTER
➜to go back to the standard display mode.
Step Input function Input value
1. Probe Select probe measuring range (see type label of
the probe) - default value is 250 mbar
______mbar
2. Fluid
(medium)
Select the medium (also refer to p. 7), e.g.:
- heating oil (default): Heat.oil
- Diesel: Diesel
- select other stored media with + / -
- or enter density value ... kg/m3
For unknown density values, see the Notes on
Programming - p. 7
__________
3. Tank
(tank shape)
Select the tank shape (also refer to p. 7+8), e.g.:
- linear (default): Linear
- cylindrical horizontal:Cyl.
- cyl. horizontal 50 to 100 m³:Cyl.>50m3
__________
4. Volume
(tank volume)
Enter tank volume (or maximum fill level):
e. g.: 20.000L
Important: Please see a volume table for the
highest value, if available.
For a 100 m
3
cyl. buried tank, this may for
example be the value 100 600 liters.
_________L
5. Height
(tank height or
max. filling
height)
Enter inner tank height in millimeters:
e. g.: 2.500 mm (max. value = 9.999 mm)
(height without dome)
Important: Please see a volume table for the
highest value, if available.
For a 100 m
3
cyl. buried tank, this may for
example be the value 288 cm = 2,880 mm.
________mm
Steps 6 + 7 are only required for SmartBox 2 and SmartBox 3
➜ SmartBox 2:
6. Relay1
or
➜ SmartBox 3:
6. Beeper (Acoustic
alarm)
Enter switchpoints as percentage from 01 to 99
(and/or as °C value from -99 to +99) - only for a
probe with temperature measuring function)
deactive ➜ activate with +/ -to
active ➜ press Enter to confirm 
On: 10% ➜ ON: set with +/ -➜ Enter
Off:12% ➜ OFF: set with +/ -➜ Enter
On ___%
Off ___%

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Article No. 28 100-
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On: +0°C ➜ ON: set with +/ -➜ Enter
Off:+0°C ➜ OFF: set with +/ -➜ Enter
Deactivate the relay or beeper via deactive
or input of 0% or 0°C (for On and Off).
On ___°C
Off ___°C
7. Relay2 See 6. Relay 1 for the data for Relay 2
8. Exit (quit) Press Enter to return to display mode
After performing entry steps 1 - 7, the programming process is completed. After confirmation of
step 8 “Exit“, the device automatically returns to standard display mode; the current tank content
is shown in the display.
Special functions are available under entry steps 9 to 13 (see page 9).
After the end of setup, do not forget to re-screw the housing cover!
Examples for programming
Example 1 Basement tank for 6000 liters heating oil, liter indication, linear steel tank
Inner height 165 cm, (fill level 125 cm)
Standard probe TDS-6023 0 – 250 mbar
Step Entries/selection
1. Probe 250 mbar 250mbar
2. Medium: heating oil Heat.oil
3. Tank shape: linear Linear
4. Tank volume: 6000 liters 6000L (set with +/- keys)
5. Inner tank height: 165 cm 1,650mm (set with +/- keys)
6. Relay 1 – no function deactive
7. Relay 2 – no function deactive
8. Exit ➜ press ENTER to see the indication ➜ e.g. 4550L
Example 2 Buried tank, cylindrical, horizontal, for 100,600 liters Diesel oil
Inner height 2.886 m, (fill level 54 cm)
Standard probe TDS-6023 0 – 250 mbar
Step Entries
1. Probe 250 mbar 250mbar
2. Medium: Diesel Diesel
3. Tank shape cyl. horizontal >50m
3
Cyl.>50m3
4. Tank volume: 100,600 liters 100,600L (exact value from volume table)
5. Inner tank height: 288 cm 2,886mm (exact value from volume table)
6. Relay 1 – no function deactive
7. Relay 2 - no function deactive
8. Exit ➜ press ENTER to see the indication ➜ e.g. 12800L
Tank with inner casing
For tanks with inner casing (e.g. cyl. horizontal or basement-welded tanks), the entries for inner
height and volume should be adjusted.
Examples:
➜ Wall thickness of inner casing 0.5 cm ➜ reduce value for inner height by approx. 1 cm, reduce
volume for 10 m³ by 1.3%, for 20 m³ by 1%, for 50 m³ by 0.8% and for 100 m³ by 0.7%.
➜ Wall thickness of inner casing 2 cm ➜ reduce value for inner height by approx. 4 cm, reduce
volume for 10 m³ by 5%, for 20 m³ by 4%, for 50 m³ by 3% and for 100 m³ by 2.5%.

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Example 3 Well, 7.50 m maximum water level from ground of the well
(fill level 4.20 m), relay switching function is desired.
Probe TDS-6029 (measuring range 0 – 1000 mbar), indication in m water column.
Step Entries
1. Probe 1000 mbar 1000mbar
2. Medium: water H2O
3. Tank shape (well shape): linear Linear
4. Max. value 7500 (indicated in m) 7,500L (set with +/- keys)
5. Inner tank height 7.50m 7,500mm (set with +/- keys)
6. Relay1 – ON at <05% - OFF at >10% active ➜ On: 05% →Off:10%
7. Relay2 – no function
8. Exit ➜ press PLUS key to go to
12. Unit – indicated unit: m Unit: m
13. Rounding: auto auto (just confirm with ENTER)
14. Exit ➜ press ENTER to see the indication ➜ e.g. 4.20m
Notes on programming
Menu item Setting Description
0.Exit Back to display mode
1.Probe
100mbar
150mbar
250mbar
500mbar
1000mbar
2000mbar
3000mbar
5000mbar
Set mbar
Cal mode
Tank height heating oil up to 1.2 m – water up to 1 m
Tank height heating oil up to 1.8 m – water up to 1.5 m
Standard probe - tank height heating oil up to 3 m – water up to 2.5 m
Tank height heating oil up to 6 m – water up to 5 m
Tank height heating oil up to 12 m – water up to 10 m
Tank height heating oil up to 24 m – water up to 20 m
Tank height heating oil up to 36 m – water up to 30 m
Tank height heating oil up to 60 m – water up to 50 m
Entry of a specific probe with different measuring range
Is only indicated if item 10. Set h or 11. Set V has been activated
2.Fluid
Medium
Heat.oil
H2O
Diesel
BioD
RME,FAME
Rapsoil
Palmoil
Motoroil
AdBlue
Normal-B
Super-B
Set kg/m3
Cal mode
845 kg/m3 - default setting
999
830
880
880 (rapeseed, methyl ester, fatty acid methyl ester)
915
910
865
1.090
743
750
Entry of a specific density value
Is only indicated if item 10. Set h or 11. Set V has been activated
If the density of the stored medium is unknown, the reference height can be entered in menu item
10. Set h. To this end, determine the current fill level in mm, deduct 10 mm from it and enter the
resulting value - click YES to confirm the entry.
Should the current fill level be smaller 75%, we urgently recommend to adjust the value after the
next refueling to achieve a good measuring accuracy.
3. tank
tank
shape
Linear Default setting
linear tank, rectangular tanks, vertical
cylinders, basement-welded steel tanks.

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Article No. 28 100-
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Page 8 of 12
Cyl. cylindrical tank (optionally, see Cyl.>50m
3
),
horizontal cylinders; tubular tanks, max. 45 m
3
;
typical shape for steel outdoor or buried tanks.
Ball spherical tank; buried tanks with spherical
basic shape; frequently plastic buried tank
(GRP).
Oval oval basement tanks; typical shape of GRP
tanks and single-walled sheet metal tanks
Convex Plastic battery tanks, convex, slightly bellied
shape, alternative to linear
Concave Plastic battery tanks, concave, slightly caved
in shape, alternative to linear
Plastic
Plastic tank with recess
Plastic tank with a large recess (hollow) in the
center (without tape bindings)

Cyl.>50m
3
large cylindrical outdoor tank 50,000 liters to
100,000 liters; a special bearing chart
conversion table can be ordered specifically
for large cylindrical tanks of 50 m
3
to 100 m
3
.
4.Volume
tank vol-
ume
xxx.xxxL
Default setting is 0 L. 0L is an invalid value.
This parameter must be set in all cases.
5.Height
Inner tank
height
x.xxx mm
(or cm)
Default setting is 2,000 mm
(Maximum value is 9,999 mm) - for probes from 1,000 mbar, the
height is indicated/set in cm, not in mm.
6.Relay1
(SBox 2)
or
deactive
active
Default setting (enter on deactive ➜go to next entry step)
Enter on active results in the next ‘On’ step
6. Beeper
(SBox 3)
On: 10%
10% is the default setting, range is 0..99
Relay or acoustic alarm alarm switches ON when the content of the
tank falls below a limit of e.g. 10%.
Off:12% 12% is the default setting (hysteresis)
Relay or acoustic alarm switches OFF again when the content of the
tank rises above a limit of e.g. 12%. When On=0% and Off=0%, no
fill level switching function is active.
On: +0C
Only if a temperature adapter is available; range is -99C .. +99C
When On=0C and Off=0C, no temperature switching function is active
Relay or acoustic alarm switches ON when the temperature falls be-
low a limit of e.g. 15°C.
Off: +0C
Relay or acoustic alarm switches OFF again when the temperature
rises above a limit of e.g. 17°C (hysteresis).
7.Relay2 For entries for Relay2, refer to 6.Relay1
8.Exit Back to display mode

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Article No. 28 100-
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Page 9 of 12
9.Offset
ESC
Calibrat
Default
Zero point adjustment (probe offset)
is indicated only after a calibration has been performed
10.Set h xxxx mm
Possibility to enter reference height for 2-point-measurement, for a
different probe measuring range, or if density is unknown.
Deduct 10 mm from the current fill level as measured*, and enter the
resulting value.
If tank height “5.Height” has been indicated in cm (e.g. for probe
measuring range from 1,000 mbar), the value will be indicated in cm
here!
Cal: No
Cal: Yes
If activated (Yes), a confirmation dialog follows because from now on,
the system will not calculate with the density as entered but with a
special factor. Then, “Cal Mode” is indicated in step 1+2.
If this entry is made while the tank is almost empty, it is advisable to
perform a readjustment later on, see 11.Set V.
11.Set V xxx.xxxL Readjustment of the fill level indication with +/- key.
Cal: No
Cal: Yes
See 10.Set h
12.Unit
Unit: L
Unit: m
3
Unit: %
Unit: m
Default setting (3 decimal points: 999,900L)
(2 decimal points: 75.50 m
3
)
(2 decimal points: 99.50 % )
(2 decimal points: 2.50 m )
13.Round
Rounding
auto
off
2
5
10
20
50
100
Default setting
(increments of 1)
In dependence on the preset volume, one or two zeros are added.
This is to say that a selected rounding value 2..100 refers to the
4
th
indicated position (e.g. for a 100,000L tank, 10= stands for 1,000L
rounding)
14. –
19. Exit
Back to display mode
20. LCD Contr 60 Set the contrast of the LCD display
21. Info Shows the following:
Software version V1.00
Serial number SN1234
X0 xxxx
B xxxx
22.TestI Indication of the current mA measured value and the hex value for the
AD converter
23.TestR Rel1 ON
Rel1 OFF
Rel2 ON
Rel2 OFF
Relay test
24.Init Sure:No
Sure:Yes
Clear all settings (factory settings)
26. Exit Back to display mode

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Error messages
Error code Significance
Error E1 The set value is invalid
Error E2 Measured value too small (<3mA => probe defective)
Error E3 Measured value too great for zero point calibration (probe must not be immersed)
Error E4 Not defined
Error E5 Not defined
Error E6 Set height is too great (measured value is too small - the probe must be immersed)
Error E7 Set volume is too great (measured value is too small - the probe must be immersed)
Error E8 Measured value is too great (probe short-circuited, defective, or incorrectly
connected)
Error E9 Measured value is 0 (no probe connected, or wire breakage, or reversed polarity)
ErrorE10 Calibration error
ErrorE11 Warning ‘Tank empty’ (tank content is actually too small for calibration) Press OK to
continue nevertheless)
Checking the level probe signal: At 0 cm fill level ➜ approx. 3.5 – 4.5 mA
Can be checked through menu item 22. For 1 m water column ➜ approx. 9 - 11 mA (for
standard probe with measuring range of 250 mbar)
OPERATION
The contents indicator does not require any attention during ongoing operation.
PERFORMANCE CHECK
After refueling the tanks or once per year, check whether the indicated value corresponds to the fill
level.
MAINTENANCE
SAFETY INFORMATION for water-polluting operating media:
Any material leakage occurring during maintenance must be collected.
Observe the respective legal regulations!
With correct installation and operation, the contents indicator is free of maintenance. The
indicator and the probe element must be checked annually, as described under PERFORMANCE
CHECK.
REPAIR
In case of repeated error or alarm message (relay output) while the tank content does not reach /
remains under the set fill level alarm threshold at the probe element, check the connection line of
the signal and probe element for breakage or short-circuit, re-install if necessary.
If the measures explained under the headings START-UP, OPERATION and MAINTENANCE fail
to achieve regular re-START, and unless the instructions have been misunderstood, the device
must be removed and sent to the manufacturer’s for a check-up. Any unauthorized handling will
result in loss of any warranty claims.

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ADDITIONAL TECHNICAL DATA
Indicator
Supply voltage 230 V AC 50 Hz Degree of protection:
IP 30 or IP 65 acc.
to IEC 529
Power input: max. 2 VA
Measuring input:
4 - 20mA ; U
0
= 20V ; Resolution:
10 Bit
Accuracy: ± 1 %
Relay output: Optional
(see accessories)
Switching voltage: max. 250 V AC Analog output: 0 - 5 V DC
Switching current max. 3.5 A 4-20 mA
Dimensions W x H x D:
in [mm]
120x120x49 (IP30)
or
130x130x60 (IP65)
Housing:
Polystyrene (IP30)
or
Polycarbonate (IP65)
Probe element (relative pressure probe for level detection)
Operating voltage: 20 V DC Degree of protection:
IP 68 acc. to IEC
529
Material: V4A ; POM;
FPM; HD-PE
Length of probe
(without cable)
90 mm
Standard version: 250 mbar
Length of probe
connection cable
6 m
Installation position: vertically suspended, or horizontally supine
Temperature range: Ambience
Operating media
0 °C to 80 °C
LIST OF ACCESSORIES
Order no. Product description Information on application
28 851-00 DTM-1 data transmission mod-
ule 0-5 V
Retrofittable module as interface to data trans-
mission, e.g. for the master control system of
the building
28 853-00 DTM-3 data transmission mod-
ule 4-20 mA
Retrofittable module as interface to data trans-
mission, e.g. for the master control system of
the building
28 856-00 PC set
Retrofit kit for data transmission to a PC – incl.
software for indication/evaluation and for send-
ing messages via e-mail
28 857-00 Cable junction box IP 66, water-
tight, with pressure equalization
To extend the probe cable - e.g. in the dome
28 500-00 SmartBox 5 - data transmitter
GSM telecommunication system for SmartBox
1, 2 or 3 and event messages (e.g. burner mal-
function)
28 858-00 Additional antenna
Additional antenna for reception amplification at
the SmartBox 5 - data transmitter

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Article No. 28 100-
Version 12.2007
Page 12 of 12
GOK Regler- und Armaturen-Gesellschaft mbH & Co. KG
Obernbreiter Straße 2-16, D-97 340 Marktbreit 

[phone] Fax [phone]
E-Mail: [e-mail] Internet: www.gok-online.de
Art.-No. 28 100-57a