DGBOX rev Inverter electronic control panels for single pumps or pumping units OPERATOR S AND MAINTENANCE MANUAL

Transcription

1 DGBOX rev. 60 EN Inverter electronic control panels for single pumps or pumping units OPERATOR S AND MAINTENANCE MANUAL Model V in V out A P (kw) P (HP) DGB MV 30 3 ~ 400V 3 ~ 400V DGB MV 55 3 ~ 400V 3 ~ 400V 4 5,5 7,5 DGB MV 75 3 ~ 400V 3 ~ 400V 8 7,5 0 DGB MVF 30 3 ~ 400V 3 ~ 400V DGB MVF 55 3 ~ 400V 3 ~ 400V ,5 + 5,5 7,5 + 7,5 DGB MVF 75 3 ~ 400V 3 ~ 400V ,5 + 7, DGB MW 30 3 ~ 400V 3 ~ 400V DGB SV 30 3 ~ 400V 3 ~ 400V DGB SV 55 3 ~ 400V 3 ~ 400V 4 5,5 7,5 DGB SV 75 3 ~ 400V 3 ~ 400V 8 7, A

2 INDEX PART QUICK INSTALLATION GUIDE SAFETY STANDARDS 3 INSTALLATION 3 POWER CONNECTIONS, PRESSURE AND FLOW SIGNAL CONNECTIONS 3 INPUT / OUTPUT SIGNAL CONNECTIONS 5 INPUT CONNECTIONS 5 OUTPUT CONNECTIONS 5 MASTER-SLAVE CONNECTIONS 5 STARTING UP 6 ACCESS TO MAIN MENU AND PARAMETER MENU 6 SELF-LEARING CONFIGURATION 7 MAIN MENU AND PARAMETER MENU 8 SETTING THE PARAMETERS REQUIRED FOR OPERATION 9 Setting the system pressure and the rated current 9 Checking the direction of rotation of the motor 0 Checking the motor frequency (default 50 Hz) Checking the maximum working frequency (default 50 Hz) Determination of the shutdown frequency setting the full scale of the pressure sensor Configuration of the flow sensor CONTROL OF DRY RUNNING IN APPLICATIONS WITHOUT FLOW SENSOR TEST 3 ALARMS 4 PARTE USER S MANUAL PRODUCT DESCRIPTION 5 GENERAL TECHNICAL DATA and WORKING LIMITS 7 DIMENSIONS AND WEIGHTS 7 MULTI-PUMPS UNITS 8 models and product identification code 9 SURGE TANK 0 SAFETY PRESSURE SWITCH 0 FUNCTIONING. CONFIGURATION.. BASIC CONFIGURATION (BASE SETUP).. ADVANCED CONFIGURAZIONE ( ADVANCED SETUP) 3.3. HARDWARE CONFIGURATION (HARDWARE SETUP) 7.4. MAINTENANCE (MAINTENANCE) 3. TEST 3 3. WORKING OUT OF SERVICE UPDATING 35 STARTING UP 37 TROUBLESHOOTING 38 WARRANTY 40 DISPOSAL 40 DECLARATION OF CONFORMITY 40

3 SAFETY STANDARDS Safety important instructions. This symbol warns that failure to comply with the prescription leads to a risk of electric shocks. This symbol warns that failure to comply with the prescription leads to a risk of injury/damage to persons/objects. Before installation and use of the product, read this manual completely and thoroughly. Installation and maintenance must be carried out by qualified staff, responsible for performing the hydraulic and electric connections according to the applicable Standards in force. The manufacturer declines all responsibility for damage deriving from improper use of the product and is not liable for damage caused by maintenance or repairs that are carried out by unqualified staff and/or using non-original spare parts. The use of non-original spare parts, tampering or improper use, make the product warranty null and void. During first installation make sure that: - the electric power supply network is not live - The electric power supply network is protected by ground connections in compliance with the Standards. When carrying out maintenance: - the electric power supply network is not live - Before removing the inverter cover or starting interventions on it, the system must be disconnected from the mains electricity and you must wait for 5 mins until the intermediate circuit condensers, which can reach voltages of up to 800V, have the time to discharge via the built-in discharge resistors. - do not disconnect the pumps if DGBOX is in operation; before you disconnect the pumps, stop the control and disconnect the power supply. Emergency stop An emergency stop can be performed while the inverter is running, by pressing the START/ key. In parallel inverters installations, only the MASTER inverter stops the whole system. INSTALLATION DGBOX must be installed in accordance with the following conditions: in a ventilated room, protected from the elements and from exposure to the sun, the side distance and height off floor are not less than those indicated in DIMENSIONS AND WEIGHT, to allow proper unit cooling near the pump - IMPORTANT: FOR APPLICATION WITH LONG CABLE BETWEEN THE INVERTER AND MOTOR, PLEASE CONSIDER FITTING AN ELECTRONIC FILTER In vertical position POWER CONNECTIONS, PRESSURE AND FLOW SIGNAL CONNECTIONS Before making the connections, make sure that the ends of the line wires are not live. Make sure also that the electric power supply network is protected by thermal magnet and differential protections according to the applicable Standard in force. The differential switch must be high-sensitivity type (30 ma in class A for domestic application, class B for industrial applications). Ground connections must be in compliance with Standards. The power supply cable must have 4 wires (3 phase + ground). The connection cable between the inverter and the motor pump must have 4 leads (3 phase leads + Earth) and be suitably shielded to comply with EMC standards. The cable must be sized to curb any power voltage drop within 3%. IMPORTANT: FOR APPLICATION WITH LONG CABLE, CONSIDER FITTING AN ELECTRONIC FILTER TO PREVENT POWER PEAKS AND WAVE DISTORSIONS GENERATED BY LONG CABLES. 3

4 DESCRIPTION OF THE MAIN COMPONENTS PRESSURE SENSOR ( DANFOSS ) PRESSURE SENSOR + FLOW SENSOR ( TEEVALVE ) Vdc 4-0 ma flow C flow NO GND Vdc 4-0 ma flow C flow NO GND PIN + PIN - brown black grey white blue DANFOSS U V W GND PUMP U V W GND PUMP R S T GND LINE TEEVALVE. Disconnection switch. Thermal magnetic switch / fuse-carrier module 3. Inverter output terminal board 4. contactor with thermal motor protection (fixed speed pump) ATTENTION: set the protection of the thermal relay to the rated current of the pump (fixed speed pump) 5. input signal terminal board (analogue + flow signal ) 6. input signal terminal board (analogue + flow signal ) 7. digital input signal terminal board IN and IN 8. digital output signal terminal board OUTPUT and OUTPUT 9. signal terminal board RS USB port. keyboard / display screen. terminal clamps fixing bar (DIN standard) 4

5 INPUT SIGNAL CONNECTIONS PRESS/FLOW + Vdc 4-0 ma Flow C. Flow N.O. 0 V PRESS/FLOW + Vdc 4-0 ma Flow C. Flow N.O. 0 V INPUT / OUTPUT SIGNAL CONNECTIONS INPUT + Vdc IN IN - C - N.C. - N.O. OUTPUT - C - N.C. - N.O. OUTPUT SIGNAL CONNECTIONS PRESS/FLOW + Vdc 4-0 ma Flow C. Flow N.O. 0 V PRESS/FLOW + Vdc 4-0 ma Flow C. Flow N.O. 0 V INPUT + Vdc IN IN max 5A 50 V - C - N.C. - N.O. OUTPUT - C RS485 D + D - 0 V - N.C. - N.O. RS485 D + D - 0 V max 5A 50 V - permits connecting two input signals of the clean-contact type - see param. INPUT CONFIG - see param. INPUT CONFIG - If the contact of the sensor (eg. a level probe) is open, the operation is inhibited - Operating current is 5 ma for each input - Max capacity from Vdc is 00 ma. - The power voltage supply (+ 4 Vdc) CANNOT be used to supply external devices. - relay outputs are available - These can be connected both with NO logic and with NC logic - see. param. OUTPUT CONFIG - see. param. OUTPUT CONFIG - The max load which can be connected is A at 50 Vac - the cable must have leads and a minimum cross-section of 0.5 square mm MASTER SLAVE CONNECTIONS permits connection and communication with external devices by means of standard RS485 USB Vdc 4-0 ma Flow C. Flow N.O. Gnd PRESS / FLOW MASTER BOARD Vdc 4-0 ma Flow C. Flow N.O. Gnd 3 + Vdc In In C 3 PRESS / FLOW INPUT OUTPUT Rs N.C. - N.O. - C - N.C - N.O. D+ D - Gnd + 4Vdc S Gnd S3 (Vac) S CS3 (Vac) SLAVE BOARD S S3 (Vac) I/O AUXILIARY +4Vdc CS3 (Vac) D+ S Gnd D - Gnd Rs 485 IN j4 D+ D - j5 Gnd Rs 485 OUT To operate the system MASTER / SLAVE is necessary to address the pump to inverter SLAVE. to address the pump to inverter SLAVE set the parameter 3. PUMP CONFIG = 3 (EXT. INV. ) The other parameters are set in SELF-LEARNING or they can be set manually.5 PUMP CURRENT (SLAVE pump protection) and.6 PUMP ROTATION.8 MIN POWERF = minimum power factor of the pump for protection against dry running. POWERF TIME = enables protection against dry running for COSFI. 5

6 STARTING UP Before running, this Manual must have been carefully read and the instructions followed; wrong settings and operations are thus prevented that could cause operating faults. After performing the operations described in the INSTALLATION chapter, the inverter can be started. Before starting the system, the pumps must be primed (filling and air bleeding). When DGBOX is energised, it enters the STARTING phase, which lasts 5 seconds, after which DGBOX returns to the same operating conditions in which it was when it was last switched off (in WORK mode or OUT OF SERVICE mode). During the STARTING phase DGBOX can be switched to OUT OF SERVICE mode or SELF-LEARNING mode as described below: WORK mode if DGBOX was in ON condition at last switch-off Power network STARTING phase (5 sec.) waiting pressing START / OUT OF SERVICE mode if DGBOX was in condition at last switch-off OUT OF SERVICE mode (suitable for manual configuration) pressing ENTER SELF-LEARNING mode (Wizard) - To manually configure DGBOX see ACCESS TO MAIN MENU AND PARAMETER MENU in this page - To configure DGBOX in SELF-LEARNING see SELF-LEARNING CONFIGURATION at page 7. ACCESS TO MAIN MENU AND PARAMETER MENU to - scroll the MAIN MENU - scroll the PARAMETER - modify the parameter values use the keys To access and exit the MENU and the parameter use the keys to access the MAIN MENU press the button SET for 3 sec. in "MAIN MENU AND PARAMETER MENU" page 8 - are highlighted parameters that must be configured for the proper functioning of DGBOX (case referred to a single pump) These parameters are described in the section "SETTING THE PARAMETERS REQUIRED FOR OPERATION page 9 6

7 SELF-LEARNING CONFIGURATION DGBOX permits setting all the parameters required for self-learning: Starting... () 5 s Press ENTER for WIZARD W IZA RD Select w orking Pressure Pum p nom inal current /8 (ENTER) (ENTER) P 3.5 Bar W IZARD /8 CU Select W IZA RD Select Pum p nom inal current W IZA RD Select Pressure Sensor Range b/8 (ENTER) 4 /8 (ENTER) 4.0 A CU 4.0 A P s Bar To access WIZARD press ENTER within 5 seconds from DGBOX switch-on Select the WORKING PRESSURE using the arrows UP/DOWN and confirm by pressing ENTER Select the PUMP RATED CURRENT using the arrows UP/DOWN and confirm by pressing ENTER If present, Select the PUMP RATED CURRENT using the arrows UP/DOWN and confirm by pressing ENTER Select the PRESSURE SENSOR FULL SCALE using the arrows UP/DOWN and confirm by pressing ENTER OPEN A TAP (e.g. 0 l/min) and press TEST TO ENABLE THE PROGRAM TO DEFINE THE CORRECT DIRECTION OF PUMP ROTATION OPEN A TAP (e.g. 0 l/min) and press TEST TO ENABLE THE PROGRAM TO DEFINE THE CORRECT DIRECTION OF PUMP ROTATION (if present) W IZA RD Pum p Rotation (Self Learning) Push Test f or start 3 /8 (ENTER) Ro C.W W IZA RD Learning /... 5s f or Exit () 3 /8 W IZA RD 3 /8 W IZA RD 3 /8 3 0 Hz. P 4.5 A Learning /... OK Learning /... 5s f or Exit () 3 0 Hz. P 4.5 A Learning /... OK Learning /... OK COM PLETED (ENTER) Ro A.C.W W IZARD 3 /8 Ro Pum p Rotation (Self Learning) Push Test f or start (ENTER) C.W W IZA RD 3 /8 Learning /... 5s for Exit () 3 0 Hz. P 4.5 A W IZA RD Learning /... OK Learning /... 5s f or Exit 3 /8 () 3 0 Hz. P 4.5 A W IZA RD Learning /... OK Learning /... OK COM PLETED 3 /8 (ENTER) Ro A.C.W WIZARD asks whether a flow sensor is fitted or not; if NOT: W IZA RD 5 /8 Fw S Flow sensor presence? Se sensore di Flusso > 0 (ENTER) 0 NO sensor Se sensore di Flusso = 0 W IZA RD Frequency (Self Learning) Push TEST for start 6 /8 W IZA RD 7 /8 (ENTER) Frequency Hz W IZA RD 6 /8 P 3.0 Bar Learning... 0 s compare solo se ho inverter anche su pompa Hz Freq. (ENTER) (ENTER) (ENTER) Premendo ENTER passo a schermata 7/8 Premendo ENTER memorizzo il valore attuale Premendo ENTER passo a schermata 7/8 M in P Fact or (Self Learning) Push TEST for start M in Pow er Fact or Premendo ENTER passo a schermata 8/8 OPEN A TAP (e.g. 0 l/min) and press TEST TO ENABLE THE PROGRAM TO DEFINE THE PUMP (and if present) SWITCH- FREQUENCY CLOSE ALL TAPS (flow = 0) and press TEST TO ENABLE THE PROGRAM TO DEFINE THE MINIMUM PUMP (and if present) COSFI W IZA RD P 3.0 Bar Learning... 0 s 7 / Pf M in Pf (ENTER) Premendo ENTER memorizzo il valore attuale W IZA RD P 3.0 Bar COM PLETED 6 /8 W IZA RD 7 /8 P 3.0 Bar COM PLETED (ENTER) Frequency Hz M in Pow er Fact or Premendo ENTER passo a schermata 8/8 W IZA RD Conf iguration COM PLETED 8 /8 ENTER f or STA RT W IZA RD 8 /8 Pum ps: Variable Speed: P :8 A - CW P : 0 A - A CW W IZA RD 8 /8 Press Sensor: 6Bar Flow Sensor: 0 Freq Of f : 3 5 hz M in Pf: 0.8 (ENTER) (ENTER) (ENTER) Premendo ENTER esco dal wizard Premendo ENTER esco dal wizard Premendo ENTER esco dal wizard ENTER f or STA RT ENTER f or STA RT 7

8 MAIN MENU and PARAMETER MENU highlighted below the parameters that must be configured for the proper functioning of DGBOX (case referred to a single pump) Menu: BASE SETUP Par. Parameter code Description u.m. Default Min Max Step. PRESSURE SET P Working pressure bar 3.5 0,5 PS 0.. PRESSURE SET P Working pressure bar.5.0 PS 0..3 PUMP CURRENT CU Nominal current pump n A PUMP ROTATION RO Rotation direction of pump n - CW CW ACW -.5 PUMP CURRENT CU Nominal current pump n A PUMP ROTATION RO Rotation direction of pump n - CW CW ACW -.7 PUMP 3 CURRENT CU3 Nominal current pump n 3 A PUMP 3 ROTATION RO3 Rotation direction of pump n 3 - CW CW ACW -.9 PUMP 4 CURRENT CU4 Nominal current pump n 4 A PUMP 4 ROTATION RO4 Rotation direction of pump n 4 - CW CW ACW -. SERIAL -FIRMW -- Serial number and firmware version Menu: ADVANCED SETUP Par. Parameter code Description u.m. Default Min Max Step. RESTART DIFF DPr Restarting differential pressure bar MOTOR FREQ MF Motor frequency Hz MIN FREQ LoF Minimum operating frequency Hz MAX FREQ HiF maximum operating frequency Hz MIN DRY PRES PD Minimum working pressure % DRY RUN TIME TD Dry operating time before error of water lack s MIN POWERF x Pump minimum cosphi - 0,0 0,00 0,0.8 MIN POWERF x Pump minimum cosphi - 0,0 0,00 0,0.9 MIN POWERF3 x Pump 3 minimum cosphi - 0,0 0,00 0,0.0 MIN POWERF4 x Pump 4 minimum cosphi - 0,0 0,00 0,0. POWERF TIME x Dry operating time before error of dry run s DRY RUN RESTART TR Time interval before restarting after error of water lack min FLOW TIMEOUT TF Delay time before stopping s RESPONSE FACTOR RF Inverter reactivity factor SWITCH FREQ SF Inverter switching frequency khz PRESSURE UNIT PU Pressure unit of measure - bar PSI bar -.7 ACCELERATION ACC variation of frequency Hz/s FREQ. SP OF Switch-off frequency with working pressure Hz 40 Fmin ** FREQ. SP OF Switch-off frequency with working pressure Hz 40 Fmin ** KP KP P.I.D control proportional coefficient KI KI P.I.D control integrative coefficient RESTORE DEFAULT - Restore of BASE and ADV parameters Menu: HARDWARE SETUP Par. Parameter code Description u.m. Default Min Max Step 3. PUMP CONFIG PC Pump configuration - 3. PUMP CONFIG PC Pump configuration PUMP 3 CONFIG P3C Pump 3 configuration PUMP 4 CONFIG P4C Pump 4 configuration INPUT CONFIG IN digital input function set INPUT CONFIG IN digital input function set OUTPUT CONFIG OU digital output function set OUTPUT CONFIG OU digital output function set ANALOG CONFIG AN Configuration of analogic input

9 3.0 PRESSURE SENSOR PrS Set up of connected pressure sensors P SENSOR F.S. PS Pressure sensor n range P SENSOR F.S. PS Pressure sensor n range FLOW SENSOR FwS Set up of connected flow sensors UNLOCK SYSTEM ULS Unlock function h VOLTAGE V Main voltage V FORCE EXCHANGE FE Forced alternation of inverters min P SENS. CALIB Calibration of pressure sensor P SENS. CALIB Calibration of pressure sensor Menu: MAINTENANCE Par. Parameter code Description 4. SERIAL NUMBER -- DGBOX serial number 4. ALARM HISTORY -- List of alarms during functioning 4.3 WORKING TIME -- Operating statistical data of working pumps 4.4 SET DATE-TIME -- Date and time setting menu. 4.5 EXTENDED MENU -- reserved for service personnel - password protected SETTING THE PARAMETERS REQUIRED FOR OPERATION SETTING THE SYSTEM PRESSURE (PRESSURE SET ) AND THE RATED CURRENT (PUMP CURRENT) 04//0 P 0.0 set 3.5 5:0 SYSTEM SET SETTING BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE BASE SETUP. PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW SET P. 3.5 Bar BASE SETUP. SET P. PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW Bar BASE SETUP. PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW SET P. 4.0 Bar BASE SETUP. SET P. PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW Bar ESC BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW CURRENT 0.0 A CURRENT 0.0 A BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW CURRENT 9.0 A BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW ESC SETTING BASE ADV SETUP HARDWARE SETUP MAINTENANCE ESC BASE SETUP PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION.3 CURRENT 9.0 A ESC SERIAL - FIIRMW

10 CHECKING THE DIRECTION OF ROTATION OF THE MOTOR (PUMP ROTATION) For surface pumps (see fig. below): switch the system to TEST mode, start it by pressing START, and look to see whether the motor fan is turning in the direction indicated on the pump body. Stop the system by pressing. 04//0 P 0.0 5:0 SYSTEM TEST 04//0 5:0 P 0.0 TEST START 04//0 P 3. TEST 5: HZ 40 V.7 A 04//0 5:0 P 0.0 SYSTEM ESC 04//0 5:0 P 0.0 TEST START If the direction of rotation does not coincide, switch it over by means of the PUMP ROTATION parameter (see fig.below). 04//0 P 0.0 5:0 SYSTEM SET MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE BASE SETUP. SET P. PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW Bar BASE SETUP.4 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW DIRECT BASE SETUP.4 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW DIRECT BASE SETUP.4 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW DIRECT ESC MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE ESC BASE SETUP.4 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW DIRECT ESC For submersible pumps (see fig. below) the system must be placed in WORK mode; start the system by pressing START, with a connected unit open; DGBOX will take the system pressure to that of set P. Once operating speed has been achieved, read and record the operating frequency to maintain the pressure of set P. 0 4 / / 0 5 :0 P 0.0 set 4.0 Bar SYSTEM START 0 4/ / 0 P 4.0 5:0 set 4.0 Bar HZ 4 0 V.8 A Now reverse the direction of rotation by means of the PUMP ROTATION parameter as indicated in the above example for surface pumps, repeat the starting operation and again record the operating frequency to maintain the SET pressure. The correct direction of rotation is that which calls for the lesser frequency to maintain the SET pressure. 0

11 CHECKING THE FREQUENCY OF ELECTRIC MOTOR (MOTOR FREQ default 50 Hz) Verify that the parameter MOTOR FREQ match the frequency of the motor plate (default 50 Hz) PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step. MOTOR FREQ MF Motor frequency Hz CHECKING THE MAXIMUM OPERATING FREQUENCY (MAX FREQ - default 50 Hz) Verify that the parameter MAX FREQ match the frequency of the motor plate (default 50 Hz) IMPORTANT: the choice of exceeding the maximum frequency is the responsibility of the installer, who must realise the consequences of raising the maximum frequency on the risks related to the motor, to the pump and to the electrical system. PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step.4 MAX FREQ HiF maximum operating frequency Hz SETTING THE FREQUENCY ( FREQ. SP) (operation without flow sensor) Verify that the parameter FREQ. SP (shutdown frequency) matches the frequency of minimum flow (flow off). IMPORTANT: If the FREQUENCY setting is too high, this will cause the pump to stop while the request is still active, and involve frequent restarts; if the setting is too low, this could cause the continuous operation of the pump even at zero flow, with pump overheating and damage. For more details on this parameter see part of the manual (PART - USER'S MANUAL) PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step Switch-off frequency with working.8 FREQ. SP OF Hz 40 Fmin pressure ** SETTING THE PRESSURE SENSOR FULL-SCALE (P SENSOR F.S.) In this parameters, the connected pressure sensors full-scale value is entered ( analogue inputs ), according to the table: 0 0 bar 6 bar 5 bar 3 40 bar 3. P SENSOR F.S. PS Pressure sensor n range SETTING THE FLOW SENSOR (FLOW SENSOR) In the presence of a flow sensor (es. TEEVALVE) set the parameter FLOW SENSOR al to value 3.3 FLOW SENSOR FwS Set up of connected flow sensors

12 CONTROL OF DRY RUNNING APPLICATIONS WITHOUT FLOW SENSOR, with one or more pumps, submersible or surface In the presence of the flow sensor, dry running is automatically detected from the inverter, which gives a DRY RUNNING alarm. In the absence of flow sensor, to detect dry running it is necessary to properly set the parameters listed below. Table setting of parameters to determine the dry running of pumps Parameter Symbol Description u.m..5 MIN DRY PRES PD.6 DRY RUN TIME TD.7 MIN POWERF x.8 MIN POWERF x.9 MIN POWERF3 x.0 MIN POWERF4 x. POWERF TIME x. DRY RUN RESTART TR Minimum operating pressure Dry operating time before error of water lack Pump minimum COSPHI Pump minimum COSPHI Pump 3 minimum COSPHI Pump 4 minimum COSPHI Dry operating time before error of dry run Time interval before restarting after error of water lack % surface pump > than positive delivery head * subs. pump > than positive delivery head * More surface pumps > than positive delivery head * More subs. pumps > than positive delivery head * s Recommended (self-learning) ** Necessary (self-learning) *** Necessary (self-learning) *** Necessary (self-learning) *** Necessary (self-learning) *** s min * The positive delivery head (geodetic Hg) is the hydrostatic pressure resulting from the maximum water level in the system. The parameter PD (% of the set pressure) should NEVER be less than the positive delivery head, otherwise the control of dry running through PD is always verified by the positive delivery head itself. EXAMPLE: 0-floors building (height of each floor = 3.5 m) the hydrostatic pressure resulting from the maximum height of the system is equal to: 0 floors x 3.5 m = 35 m = 3.5 bar (positive delivery head) If PSET = 7 bar, then PD must be HIGHER than 50% (7 bar x 50% = 3.5 bar). By setting PD = 60% (correct), the pressure corresponding alarm is 7 x 60% = 4. bar; if the operating pressure falls below 4. bar, DGBOX stops for DRY RUNNING. By setting PD = 40% (mistake), the pressure corresponding alarm is 7 x 40% =.8 bar, but this pressure is ALWAYS GUARANTEED BY the positive delivery head (hydrostatic pressure of 3.5 bar), and therefore DGBOX should NOT detect any dry running. ** Parameter PD, when properly set, it is sufficient to detect a state of dry running with one pump; for security, we should also use the power factor COSPHI, which detects if the motor is running without any load, and stops the pump immediately. *** Parameter PD is NOT sufficient to detect a state of dry running with multiple pumps; It is therefore NECESSARY also use the power factor COSPHI (for every single pump), which detects if the motor is running without any load, and stops the pump immediately.

13 TEST - permits performing a FUNCTIONAL TEST of the pumps, both the variable-speed pump and the fixed-speed pump - It is automatically interrupted if not operations are performed from the keyboard for over 60 seconds; DGBOX automatically returns to OUT OF SERVICE mode. - To access the TEST mode, put the DGBOX in OUT OF SERVICE mode and then press the TEST key (see fig. below). - In model MW30 use the UP/DOWN arrows to select the pump to test (pump or ). Variable-speed pump: when the test is started, the pump works at MINIMUM FREQUENCY. The only possible operation is to manually INCREASE and subsequently DECREASE the work frequency (see fig. below) to gradually and reliably determine maximum pump performance. The exit from TEST mode can be done by stopping the pump () and strike ESC, or strike ESC only; DGBOX will exit from TEST mode and will stop the pump, and then return to OUT OF SERVICE mode. 04//0 5: HZ 40 V 0.0 A START 04//0 5:0 SYSTEM TEST 04//0 TEST 5:0 START 04//0 5:0 TEST 30.0 HZ 40 V.7 A 04//0 P 4. TEST 5:0 3.0 HZ 40 V.8 A.0 Hz.0 Hz 04//0 P 4. 5:0 SYSTEM ESC 04//0 5:0 P 4. TEST START 04//0 5:0 P 4. SYSTEM ESC Fixed-speed pump: to switch to fixed-speed pump from TEST mode, press the upward arrow (switch to pump see fig. below); when the test starts, the pump works at 50 Hz. The only possible operation is to SWITCH the pump ON or to determine its performance. 04//0 5: HZ 40 V 0.0 A START 04//0 5:0 SYSTEM TEST 04//0 5:0 TEST 04//0 TEST 5:0 START 04//0 P 7.6 TEST 5: HZ 40 V A 04//0 5:0 P 4. SYSTEM ESC 04//0 P 4. TEST 5:0 START 04//0 P 4. 5:0 SYSTEM ESC 3

14 ALARMS DGBOX performs continuous checks of the electrical and operating parameters, thus ensuring the protection of the pump and the inverter itself from all types of common faults. It also distinguishes between slight and serious faults and acts accordingly, by either stopping the pump or not, emitting a luminous signal and showing a message on the display screen. OVER C. 30% CURRENT LIMIT DRY RUNNING LOW LEVEL PHASE ERROR COM ERROR DRY RUNNING P SENSE ERROR PHASE ERROR ExT. UNDER VOLTAGE UNDER VOLTAGE HIGH TEMP HIGH TEMP HIGH TEMP DRY RUNNING LOW LEVEL OVERCURRENT: excessive current absorption, referred to the set value in parameter PUMP x CURRENT. DGBOX stops the system, indicating OVERCURRENT message. Re-arm is only manual by pressing ESC. CURRENT LIMIT: current absorption has exceeded inverter capacity or the thermal overload relay of the fixed-speed pump (pump ) has tripped ; DGBOX immediately stops the overloaded pump and indicates CURRENT LIMIT and the stopped pump. Re-arm is only manual by pressing ESC. DRY RUN: this occurs when there is no water at suction or suction is blocked. DGBOX stops the system and indicates DRY RUN. At scheduled time intervals, DGBOX attempts automatic start-ups. Manual re-arm by pressing ESC. WATER LEVEL: this occurs when a digital input is configured as WATER LEVEL (level signal) and there is no signal. When the signal returns, the message disappears and the inverter operates normally again. PHASE ERROR: lack of a phase towards the motor during operation. The inverter detects that one of the motor supply phases is absent, the pump is stopped and the message PHASE ERROR is displayed. Re-arm is only manual by pressing ESC. NO COM: communication has been interrupted between the control board and the power board; the causes could be the integrity of the cable and of the connection ports or an electronic board fault. DRY RUN PF: this occurs when the parameter COSPHI detects a dry running. DGBOX stops the system and indicates DRY RUN PF. At scheduled time intervals, DGBOX attempts automatic start-ups. Manual re-arm by pressing ESC. P SENSE ERROR: there is no pressure sensor signal or this is outside the sensor range and therefore wrong. DGBOX stops the system and indicates the P SENSE ERROR message. INPUT ERROR: wrong power wiring. The inverter detects that the power connections are reversed and doesn t start the pump. the message "INPUT ERROR" is displayed; reset is possible only by correcting the wiring EXT : this occurs when a digital input is configured as EXT ENABLE (control enabled from outside) and there is no signal. When the signal returns (external enabling) the message disappears and the inverter operates normally again. LOW VOLTAGE: voltage drop or voltage reduction below the minimum operating threshold. DGBOX stops the system and displays the "LOW VOLTAGE" message. Reset is automatic only after 60 sec. OVER VOLTAGE: a voltage peak has occurred over maximum operating threshold. DGBOX stops the system and indicates the OVER VOLTAGE message. Reset is automatic only after 60 sec. OVER TEMP MOD: overheating of the inverter module has occurred; the inverter stops the system, indicating the OVER TEMP MOD message. Reset is automatic, but the module temperature must have returned below the safety threshold. OVER TEMP CAP: overheating of the inverter capacitors has occurred; the inverter stops the system, indicating the OVER TEMP CAP message. Reset is automatic, but the capacitor temperature must have returned below the safety threshold. OVER TEMP BOX: overheating of the inverter box has occurred; the inverter stops the system, indicating the OVER TEMP BOX message. Reset is automatic, but the internal box temperature must have returned below the safety threshold. i-dry (only for applications with flow sensor): if the working pressure P has been set too high for the pump capacity, DGBOX still allows the system to operate with an alarm signal i-dry. LOW PRESS: (only for application with flow sensor): this occurs when the system does not reach a minimum pressure, in presence of flow (therefore excluding the operation in DRY RUNNING). Re-arm is only manual by pressing ESC. 4

15 PART USER S MANUAL GENERAL REMARKS DGBOX is a range of ELECTRONIC CONTROL PANELS for single pumps or pumping units. DGBOX is powered by three-phase 400 Va.c. (optional version 30 Va.c.) and drives motor pumps with three-phase 400 Va.c. (or 30 Va.c.) motors. It maintains the system at constant pressure at a level defined by the linked unit and adapts pump or pumping unit performance to the instantaneous requirement. A second operating pressure can also be defined, which can be enabled by means of an external signal. It carries out continuous controls on electric and functioning parameters, saving the pumping unit from all common failures (over-currents, dry running, etc) It works in stand-alone configuration or in parallel with other units, through serial connection. in parallel configuration with other units, DGBOX makes the alternation in starting the pumps Disconnection switch. Thermal magnetic switch / fuse-carrier module 3. Inverter output terminal board 4. remote switch with motor thermal cutout (fixed-speed pump outlet) 5. input signal terminal board (analogue + flow signal ) 6. input signal terminal board (analogue + flow signal ) 7. digital input signal terminal board IN and IN 8. digital output signal terminal board OUTPUT and OUTPUT 9. signal terminal board RS USB port. keyboard / display screen. cooling air inlet 3. cooling air outlet 4. terminal clamps fixing bar (DIN standard) 5

16 CONTROL PANEL This comprises a backlit graphic display screen, a membrane keyboard and two signal LEDs The POWER LED (8) is the red networking indicator light. The STATUS LED (9) is the green start-of-at-least-one-pump indicator light.. display. scrolling arrows ( UP / DOWN/ RIGHT / LEFT ) 3. SET button 4. exit button 5. TEST botton 6. confirm button 7. START/ button 8. POWER led 9. STATUS led EMERGENCY ELECTRONIC BOARD V + F models are provided with the EMERGENCY BOARD. The EMERGENCY BOARD allows to bypass the electronic control of DGBOX, and work with only the second pump, controlled by means of a mechanical pressure switch connected on the delivery pipe. The EMERGENCY BOARD is activated by pushing the switch shown in Fig..3 below. The mechanical pressure switch is connected to terminal shown in fig. below. In installations with EMERGENCY BOARD must be provided an autoclave, the volume normally matched to the characteristics of the pump. fig..3 6

17 Power supply voltage Power supply frequency output voltage output fequency Enclosure Working position Fire / explosion hazard TECHNICAL DATA and WORKING LIMITS Environment temp. max / min +45 C /-0 C Storage temp. max / min +50 C /-0 C Voltage supply tension range + /- 0% Three-phase 400 Vac (Three-phase 30 Vac) Hz Three-phase 400 Vac (Three-phase 30 Vac) 0 70 Hz IP54 vertical DGBOX units are not suitable for use in environments with risk of explosion. DIMENSIONS and WEIGHTS weight: mod. DGB M xx 30 0,5 kg mod. DGB M xx 55 3 kg mod. DGB M xx 75 3 kg Packaging dimensions : 560 x 40 x 300 mm min. 00 min O min. 7

18 MULTI-PUMPS SYSTEMS system: inverter model description VARIABLE speed pump MV 30 MV 55 MV 75 VARIABLE speed pump + FIXED speed pump VARIABLE speed pumps MVF 30 MVF 55 MVF 75 MW 30 VARIABLE speed pumps MV 55 + SV 55 MV 75 + SV 75 3 VARIABLE speed pumps MW 30 + SV 30 3 VARIABLE speed pumps MV 55 + x SV 55 MV 75 + x SV 75 4 VARIABLE speed pumps MW 30 + SW 30 4 VARIABLE speed pumps MV x SV 55 MV x SV 75 8

19 PRODUCT MODELS AND IDENTIFICATION CODES DGB MVF 75 Product family (DGBOX) Master / slave unit (M = master, S = slave) First pump - variable speed (V) Second pump fixed speed (F) Power in kw x 0 (ex. 75 = 7,5 kw) Models MV and SV ( variable speed pump) model MV 30 MV 55 MV 75 SV 30 SV 55 SV 75 Maximum motor rated 400 V a.c. kw Maximum motor rated V a.c. kw Maximum current A Three-phase voltage V 400 +/- 0% (30 +/- 0%) input frequency Hz max nominal current A Three-phase voltage V 400 (30) output frequency Hz 0 --> max nominal current A Main circuit breaker nominal current A Thermal magnetic switch nominal current A > > 3 Fuse module nominal current A Models MVF ( variable speed pump and fixed speed pump) model MVF 30 MVF 55 MVF 75 Maximum motor rated power (single 400 Va.c. kw Maximum motor rated power (single V a.c. kw Maximum current (single pump) A Three-phase voltage V 400 +/- 0% (30 +/- 0%) input frequency Hz max nominal current A output Three-phase voltage V 400 (30) (variable Frequency (variable speed pump) Hz 0 --> speed pump) max nominal current A output (fixed speed pump) Three-phase voltage V 400 Frequency (fixed speed pump) Hz max nominal current A Main circuit breaker nominal current A Thermal magnetic switch nominal current (inverter protection) A > > 3 Fuse module nominal current (inverter protection) A contactor nominal power (fixed speed pump protection) kw

20 Model MW ( variable speed pumps ) model MWF 30 Maximum motor rated power (single 400 Va.c. kw 3.0 Maximum motor rated power (single V a.c. kw.7 Maximum current (single pump) A 8.0 Three-phase voltage V 400 +/- 0% (30 +/- 0%) input frequency Hz max nominal current A 6.0 output Three-phase voltage V 400 (30) (variable speed Frequency (variable speed pump ) Hz 0 --> pump ) max nominal current A 8.0 output (variable speed pump ) Three-phase voltage Hz 400 (30) Frequency (variable speed pump ) A 0 --> max nominal current kw 8.0 Main circuit breaker nominal current A 40 Thermal magnetic switch nominal current A - Fuse module nominal current A 0 SURGE TANK A surge tank of minimum volume is necessary even when an inverter is used and this for two main reasons:. to avoid that each small requirement of the linked unit, or a small leak, cause repeated pumps starts.. to absorb any overpressures from the system, due to sudden maneuvers and stops, etc. SURGE TANK VOLUME By using diaphragm tanks, a total tank volume, expressed in litres, of not below 0% of the single pump flow rate, expressed in litres/ min., is quite adequate. For example, a unit equipped with pumps with a maximum flow rate of 00 l/min (single pump) and standard application, requires a tank with volume of: Vt = 00 x 0% = 0 litres The resulting value must be rounded up to the nearest size on the market. SURGE TANK INFLATING PRESSURE The tank must be pre-inflated, in the absence of back pressure system (no system pressure) to a pressure of 70% compared to the working pressure of the inverter For example, a unit working at 5 bar in a standard application requires an inflating pressure of: P tank = 5 bar x 70% = 3.5 bar SAFETY PRESSURE SWITCH In order to ensure that the plant pressure never exceeds a certain limit, even in the case of incorrect user maneuvers, a normal mechanical pressure switch can be connected as an input signal (INPUT, see fig. aside). - Adjusting the mechanical pressure switch to the maximum tolerable pressure from the system - and programming parameter 3.5 (INPUT CONFIG) or 3.6 (INPUT CONFIG) to the value (EXT ENABLE - menu 3 HARDWARE SETUP menu) The inverter will be switched off by the pressure switch whenever the safety pressure is accidentally exceeded. When the pressure drops below the critical value, restoration is immediate and automatic 0

21 DGBOX has five different OPERATING MODES: OPERATING MODES mode description. CONFIGURATION To access and modify the working parameters; can also be performed during operation of the system (system mode WORK), while for particular parameters editing is possible only mode OUT OF SERIVCE.. TEST For the manual testing of the pumps; the test mode is automatically interrupted if no operations are performed on the keyboard for more than 60 seconds. 3. WORK is the normal operating mode; all the operating parameters are controlled, and the main parameters and alarm messages are displayed. If during normal operation overloads occur (current or thermal), DGBOX does not stop the pumps immediately, but automatically reduces the operating frequency until the parameters are returned to their normal values 4. OUT OF SERVICE to stop the system manually, press the START / ; to manually disable the single pump, select it and choose the option. 5. UPDATE By means of a normal USB memory it is possible: - to download the error message record history - to download the set configuration to transfer it to other analogous DGBOX applications - to update the FIRMWARE currently loaded on the power and control boards with other later-issue ones. The operating modes are detailed below.. CONFIGURATION The CONFIGURATION MODE is divided in:.. BASIC CONFIGURATION (BASE SETUP).. ADVANCED CONFIGURATION (ADV SETUP).3. HARDWARE CONFIGURATION (HARDWARE SETUP).4. MAINTENANCE (MAINTENANCE) To access the CONFIGURATION MODE press the SET key. To SCROLL the MENU or the PARAMETERS, or modify the parameters value, use the keys: To ACCESS and EXIT the MENU and the PARAMETERS use the keys: To ACCESS the main MENU Press the SET button for 3 sec.

22 BASIC CONFIGURATION (BASE SETUP). PRESSURE SET P Working pressure bar 3.5 0,5 * 0. * the maximum set pressure depends from the connected pressure sensor full scale P is the MAIN operating pressure; the DGBOX control will drive the connected pumps to keep the system at the selected pressure. The required pressure must be set in agreement with pump performance. In the case of operation without flow sensor (see parameter FLOW SENSOR), together with the operating pressure P, the parameter FREQ SP will also have to be set; this sets the off frequency (see parameter.8 FREQ SP).. PRESSURE SET P Working pressure bar.5.0 * 0. * the maximum set pressure depends from the connected pressure sensor full scale P is the second work pressure. Operation with the second work pressure is started by the external control connected to the digital input IN or IN (see parameters 3.5/3.6). The required pressure must be set in accord with the pump performance. In the case of operation without flow sensor (see parameter FLOW SENSOR), together with the second work pressure P, the parameter FREQ SP must also be set. This sets the stop frequency (see parameter.9 FREQ SP)..3 PUMP CURRENT CU Nominal current pump n A * * * 0..5 PUMP CURRENT CU Nominal current pump n A * * * 0..7 PUMP 3 CURRENT CU3 Nominal current pump n 3 A * * * 0..9 PUMP 4 CURRENT CU4 Nominal current pump n 4 A * * * 0. Rated current of the pump motor. This figure determines the ammeter protection of the motor pump and must coincide with the motor plate current. * the values vary according to the power of the inverter taken into consideration..4 PUMP ROTATION RO Rotation direction of pump n - CW CW ACW -.6 PUMP ROTATION RO Rotation direction of pump n - CW CW ACW -.8 PUMP 3 ROTATION RO3 Rotation direction of pump n 3 - CW CW ACW -.0 PUMP 4 ROTATION RO4 Rotation direction of pump n 4 - CW CW ACW - Direction of rotation of pump : permits electronically changing the direction of rotation without having to switch over the wires on the terminal board.. SERIAL -FIRMW -- Serial number and firmware version DGBOX serial number and firmware version of the control board.

23 EXAMPLE: modifying the parameter PUMP CURRENT 04//0 5: HZ 40 V 5.5 A SET MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE BASE SETUP. P PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW Bar BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW CU 0.0 A BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW CU 0.0 A BASE SETUP.3 CU PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION 9.5 A SERIAL - FIIRMW ESC MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE ESC BASE SETUP.3 PRESSURE SET PRESSURE SET PUMP CURRENT PUMP ROTATION SERIAL - FIIRMW CU 9.5 A ESC.. ADVANCED CONFIGURATION (ADVANCED SETUP) The ADVANCED SETUP menu groups together the parameters which allow optimising operation in particular plant engineering situations. The setting of certain parameters requires precise plant engineering skill and wrong configuration could worsen control behaviour.. RESTART DIFF DPr Restarting differential pressure bar The DPr value determines the pump restart pressure given a certain set pressure P example: PRESSURE SET (P) = 3,0 bar RESTART DIFF ( DPr) = 0, bar Re-starting pressure = 3,0-0, =,8 The pump will start when the plant pressure drops below.8 bar.. MOTOR FREQ MF Motor frequency Hz motor plate frequency.3 MIN FREQ LoF Minimum operating frequency Hz The parameter limits the minimum operating frequency of the pump controlled by the inverter;.4 MAX FREQ HiF maximum operating frequency Hz The parameter limits the maximum operating frequency of the pump controlled by the inverter; the maximum frequency must normally coincide with the plate frequency of the motor pump (50 or 60 Hz), but the possibility exists of this varying down or up by +/- 0 Hz, with Hz step. IMPORTANT: the choice of exceeding the maximum frequency is the responsibility of the installer, who must realise the consequences of raising the maximum frequency on the risks related to the motor, to the pump and to the electrical system. 3

24 .5 MIN DRY PRES PD Minimum working pressure % The parameter configures the minimum pressure must always be achieved by the system within the time TD (TD see next parameter.5 DRY RUN TIME); is expressed as a percentage of the working pressure (P), and if is not achieved within the time TD, it means that the system is DRY RUNNING. Dry operating time before error of.6 DRY RUN TIME TD s water lack The parameter configures the maximum dry operating time of the pump before this is stopped and the DRY RUNNING error is displayed on the pump which had been running dry. Known as dry running is the situation in which the selected pressure has not been achieved and water flow is not detected in the pump. To prevent stops due to false alarms, a suitable DRY RUN TIME parameter is 0 sec. NOTE. By setting DRY RUN TIME at zero, the control function of dry operation is eliminated..7 MIN POWERF x Pump minimum cosphi MIN POWERF x Pump minimum cosphi MIN POWERF3 x Pump 3 minimum cosphi MIN POWERF4 x Pump 4 minimum cosphi The parameter configures the value of the electrical parameter COSPHI (power factor) corresponding to operation of the pump to dry (in the complete absence of water) with a further safety margin of 0,03 e.g. if cosphi to dry = 0,60 the parameter MIN POWERF = 0,60-0,03 = 0,57 Dry operating time before error of dry. POWERF TIME x s run. This parameter configures the maximum time to "dry run" of the pump, before stop and display the error DRY RUNNING COSPHI It defines dry run the situation in which DGBOX detects the operation of the motor in the total absence of load (rotor dry) DRY RUN Time interval before restarting after TR min RESTART error of water lack The parameter sets the standby time before resetting the alarm and again starting the pump in which dry operation was detected. NOTE By setting DRY RUN RESTART at zero, the automatic restart function is eliminated. Such restart must be made manually..3 FLOW TIMEOUT TF Delay time before stopping s 5 5 Indicates the delay time before stopping the pump when the set pressure has been achieved and the flow request has ceased. 4

25 PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step RESPONSE.4 RF Inverter reactivity factor - 5 FACTOR The reactivity factor indicates the DGBOX response velocity, to return to set pressure, compared to pressure variations in the plant due to linked-unit withdrawal. The values that can be selected go from (slow reaction, suitable for large-inertia plants or with possible resonance phenomena) to 5 (very fast reaction, suitable in case of fast changes in system pressure). PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step.5 SWITCH FREQ SF Inverter switching frequency khz 8 4 The parameter defines the switch-over frequency of the inverter used to produce the waveform which will supply the motor. The switching frequency can be selected between 4 khz and khz. This frequency, in the absence of a sinusoid electronic filter on the cable coming out of the motor, must be reduced together with any increase in the length of the cable itself. NOTE The length of the cable must not in any case exceed 0 m without the use of a sinusoid filter. PARAMETER SYMBOL SHORT DESCRIPTION UNIT default - - step.6 PRESSURE UNIT PU Pressure unit of measure - bar PSI bar - The parameter permits selecting the unit of measurement of the pressure displayed on the display screen (bar or psi). PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step.7 ACCELERATION ACC Speed of variation of frequency Hz/s The parameter regulates the speed of variation of the inverter frequency and consequently the speed at which the pump switches to the required speed. Acceleration is represented in Hz/s (Hz per second) and indicates by how many Hz the speed of rotation of the pump varies within the unit of time. example: ACCELERATION = 5 the parameter indicates a pump acceleration of 5 Hz per second. It follows that, starting with a state of pump stopped, it will take s to reach the speed of 50 Hz. This parameter, if regulated at minimum (0Hz/s) permits starting pumps with large inertia (PD ) without excessive current absorption at breakaway. NOTE. The parameter ACC is automatically changed when regulating the RF parameter (see parameter.7 RESPONSE FACTOR); such operation is performed to adapt acceleration to device response requirements. PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step.8 FREQ. SP OF Switch-off frequency with working pressure Hz 40 Fmin ** FREQ. SP OF Switch-off frequency with working pressure Hz 40 Fmin ** This parameter must be set only with operation without flow sensor (see - FLOW SENSOR parameter 3.3). The parameter defines the frequency below which it is considered there is no more flow request and therefore, after a time defined by the FLOW TIMEOUT parameter (see parameter.6 FLOW TIMEOUT) the pump must be stopped. the frequency below which it is considered there is no more flow request (switch-off frequency) depends on the selected work pressure. 5

26 The FREQUENCY setting relates to each PRESSURE SET operating pressure, and so if PRESSURE SET (see parameter. PRESSURE SET ) is also used, the FREQUENCY parameter will also have to be set. The FREQUENCY setting is automatically changed every time the PRESSURE SET operating pressure is changed, and it is moved to the new frequency below which it is considered that there is no more flow request. If the FREQUENCY parameter has been set, the symbol on the display screen is the waveform (see fig. below). 04/ /0 5: HZ 40 V 5.8 A 08// :7! 45.0 HZ 40 V 5.8 A FREQUENCY parameter set FREQUENCY parameter not set The FREQUENCY setting can be manual or in self-learning. Manual setting: a switch-off frequency will have to have been defined. Move to advanced configuration mode ADV SETUP (see para. 4.3 fig. 4.8), select the FREQ SP parameter (or FREQ SP depending on the set pressure) and set the switch-off frequency. IMPORTANT: If the FREQUENCY setting is too high, this will cause the pump to stop while the request is still active, and involve frequent restarts; if the setting is too low, this could cause the continuous operation of the pump even at zero flow, with pump overheating and damage. Setting in self-learning: from WORK mode and with the pump operating: - bring the system to switch-off flow rate (rate below which it is thought there is no more flow request); to this flow rate corresponds a switch-off frequency (indicated as 7.8 Hz in the illustration below) - hit the TEST key - the display screen shows the current switch-off frequency (selected) and the default value (40 Hz). - confirm the current switch-off frequency with ENTER - Save the choice (YES) and confirm with ENTER. 04//0 5:0 P.4 set.4 Bar! 7.8 HZ 40 V 5.5 A 08// :7 08// :7 P.4! FR SAVE? 7.8 HZ P HZ TEST set.4 Bar ENTER set.4 Bar ENTER Old -YES HZ -NO- 08// P.4 :7 set.4 Bar SAVE? 7.8 HZ -YES- -NO- ENTER ** IMPORTANT: THE SWITCH- FREQUENCY MUST NECESSARILY BE HIGHER OR THE SAME AS THE MINIMUM FREQUENCY. IN THE EVENT OF THE MINIMUM FREQUENCY (LOF) BEING RAISED, THE DGBOX CONTROL BOARD WILL ALSO ADAPT THE FREQ IF REQUIRED. 6

27 PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step.0 KP KP P.I.D control proportional coefficient KI KI P.I.D control integrative coefficient IMPORTANT: THE PARAMETERS KI and KP ARE CRITICAL BECAUSE THEY CHANGE THE BEHAVIOUR OF THE INVERTER, AND WRONG SETTING CAN CAUSE SYSTEM MALFUNCTIONING The parameters KP and KI constantly define the operating frequency of the inverter-controlled pump, depending on the fluctuation of system pressure compared to the set pressure. The more the system is elastic, the greater the proportionate parameter must be. The more rigid the system is, the smaller the proportionate parameter must be. Limits vary from to 50 with step. The integrative parameter must be higher in the presence of fast changes in system pressure and lower in the presence of pressure oscillations. Limits vary from 0 to 50 with step. NOTE. The parameters KP and KI are automatically changed when any changes are made to the RF parameter (see.7 RESPONSE FACTOR parameter); this operation is performed to adapt the speed of response of the device. PARAMETER SYMBOL SHORT DESCRIPTION UNIT default min Max step. RESTORE DEFAULT - Restore of BASE and ADV parameters By means of this function, the parameters entered in the BASE SETUP and ADV SETUP menus are reset to factory setting, while the HARDWARE SETUP parameters are not reset. To reset all the parameters, including the HARDWARE SETUP parameters, the function in the EXTENDED MENU must be used; use of the menu protected by password is restricted to after-sales centres or the factory... HARDWARE CONFIGURATION (HARDWARE SETUP) This menu contains all the parameters needed to set up the signal inputs and outputs on the control board. The control logics of the flow and pressure signal and type of connected sensors can also be set up. 3. PUMP CONFIG PC Pump configuration - - The parameter is fixed, pump is connected by default to the inverter 3. PUMP CONFIG PC Pump configuration - * 0 3 Default setting depends from the model. In case of DEFAULT RESTORE the parameter is = 0 The parameter makes it possible to set up the pump connection The functions that can be assigned are: 0 NO FUNCTION Pump is disabled (factory setting for models MV ) INTERNAL CONTACTOR INVERTER 3 EXT. INV. Pump is connected to internal connector (factory setting for models MVF ) and works at fixed speed. Pump is connected to internal inverter (factory setting for models MW ) and works at variable speed. Pump is connected to SLAVE unit and works at variable speed. 3.3 PUMP 3 CONFIG P3C Pump 3 configuration The parameter makes it possible to set up the pump 3 connection. The assignable functions are: 0 NO FUNCTION Pump 3 is disabled (factory setting) EXT. INV. 3 Pump 3 is connected to the inverter SLAVE and works at variable speed 7

28 3.4 PUMP 4 CONFIG P4C Pump 4 configuration The parameter makes it possible to set up the pump 4 connection. The assignable functions are: 0 NO FUNCTION Pump 4 is disabled (factory setting) EXT. INV. 4 Pump 4 is connected to the inverter SLAVE 3 and works at variable speed 3.5 INPUT CONFIG IN digital input function set INPUT CONFIG IN digital input function set The parameters make it possible to set up the function to be attributed to the digital inputs IN and IN on the control board. The functions that can be assigned to each input are: NO FUNCTION WATER LEVEL EXT ENABLE PRESS SET FLOW SIGN No function; the input state is ignored Level signal input; if the level sensor contact is open, the control remains stopped, in alarm state, and the message LOW LEVEL appears on the screen. If the level sensor contact is closed, the alarm disappears and the control starts to work normally again. Start and disabling of control by means of external signal: if the signal is not enabled, the control does not start and the message EXT appears. Enabling input of the second pressure level P (see para parameter. / PRESSURE SET ); the active signal enables the switch to the second operating pressure set in the PRESSURE SET parameter; the inactive signal switches back to the main PRESSURE SET pressure. Auxiliary flow signal input; this input configuration can be used to connect a clean-contact type flow signal connection, and with NO logic (when there is no flow, the signal is not active. When there is flow, the signal is active). 5 SLAVE Enabling input of the SLAVE signal (ON/) 3.7 OUTPUT CONFIG OU digital output function set OUTPUT CONFIG OU digital output function set The parameters make it possible to set up the function to be attributed to the output relays on the control board. The output signal is provided by relay with contacts C/NO/NC. The maximum load connectable to the relay must not exceed 5 A and 50 Vac. The functions that can be assigned to each output are: 0 NO FUNCTION No function. The state of the output is never activated. ALARM Alarm output. The output starts to indicate the condition of stop due to fault. RUN 3 ANTI FREEZE 4 PRE - ALARM Pump operating output. The output starts to indicate there is at least one operating pump. the output is active at programmed intervals; the output can be used to command a solenoid valve, which starts the recirculation of the liquid under pressure and thus starts the system pump, to prevent the pump and the hoses from freezing. Output signal of pump running in frequency limitation for excessive absorption or temperature rise. 8

29 3.9 ANALOG CONFIG AN Configuration of analogic input The analogue input can be set up in different modes: ma The input is set up to read an analogue signal from 4 to 0 ma 0-0 Vdc The input is set up to read an analogue signal from 0 to +0 Vdc 3.0 PRESSURE SENSOR PrS Set up of connected pressure sensors - 5 This parameter sets up the number of pressure sensors in the system and the reading priority assigned to each sensor. The possible choices are: 3 n Pressure sensor n Pressure sensors, mode n Pressure sensors, mode 4 Diff - 5 Diff - No. pressure sensor is connected at the analogue input ; in case of a fault affecting the pressure sensor (no signal from pressure sensor), the system is stopped and the message PRESSURE SENSOR ERROR is shown. pressure sensors are located at analogue inputs and ; pressure reading priority is assigned to sensor ; in case of a fault affecting pressure sensor, the system automatically goes on to read the data provided by the pressure sensor pressure sensors are located at analogue inputs and ; pressure reading priority is assigned to the sensor ; in case of a fault affecting the pressure sensor, the system automatically goes on to read the data provided by the pressure sensor. No. pressure sensors connected to the analog inputs and ; the pressure value is the difference between the value of pressure sensor and the sensor value (difference); the operating logic becomes that of the circulator No. pressure sensors connected to the analog inputs and ; the pressure value is the difference between the value of pressure sensor and the sensor value (difference); the operating logic becomes that of the circulator PARAMETER SYMBOL SHORT DESCRIPTION UNIT defaul t min max step 3. P SENSOR F.S. PS Pressure sensor n range P SENSOR F.S. PS Pressure sensor n range - 3 In these parameters, the connected pressure sensors full-scale value is entered ( analogue inputs and ), according to the table: 0 0 bar 6 bar 5 bar 3 40 bar 3.3 FLOW SENSOR FwS Set up of connected flow sensors This parameter sets up the number of flow sensors in the system and the flow control logic used by the system. The possible choices are: 0 NO SENSOR n FLOW SENSOR n FLOW SENSORS no connected flow sensor; because there is no sensor, DGBOX uses the FREQUENCY parameter to stop the pump at determinate frequency levels. flow sensor is connected. In this case, the sensor must necessarily be positioned immediately downstream of the delivery mouth of pump (at variable speed) flow sensors are connected. In this case, each of the pumps has the flow sensor immediately downstream of the delivery mouth and the DRY RUNNING operation of each pump can be distinguished. 9

30 3.4 UNLOCK SYSTEM ULS Unlock function h UNLOCK SYSTEM: the UNLOCK SYSTEM function prevents the blockage of the mechanical seal or other rotating pump parts, caused by long stoppage periods. If enabled (by setting the ULS parameter from to 99 hours, with h step), the function starts the pumps for 5 sec. at preset time intervals. Each pump is controlled independently from the other, and the time count is reset at every start-up. The variable-speed pump is started at minimum set frequency, while the fixed-speed pump is started at 50 Hz. By setting ULS = 0, the function is disabled. 3.5 VOLTAGE V Main voltage V Nominal supply voltage (main voltage) 3.6 FORCE EXCHANGE FE min This parameter forces the alternation of the pumps, every x minutes (programmable), in a variable speed group. By setting the parameter to zero the function is disabled It is typically used in groups, to hold in activity the reserve pump, which in normal operation would never start. 3.7 P SENS. CALIB x Calibration of pressure sensor P SENS. CALIB x Calibration of pressure sensor This parameters allow calibration (or recalibration) of the pressure sensors and, directly on the system, by calibrating the zero (ZERO CALIB) and a reference pressure of your choice (REFERENCE VAL.), or back to the factory calibration (STANDARD CALIB.) You must have a pressure gauge auxiliary reference. - Zero calibration (ZERO CALIB):. bring the system pressure to ZERO bar and check that the auxiliary pressure gauge reads zero bar.. enter the parameter ZERO CALIB pressing RIGHT arrow 3. Confirm the pressure zero by pressing ENTER - Calibration of the reference value (REFERENCE VALUE). enter the parameter REFERENCE VALUE pressing RIGHT arrow. set the reference pressure by changing the default value (5.0 bar) with the UP / DOWN arrows 3. Press START to start the pump 4. adjust the speed of the pump with the RIGHT / LEFT arrows until the auxiliary manometer indicates the reference pressure set 5. when the auxiliary manometer indicates the set pressure, confirm the reference pressure by pressing ENTER 6. return to automatic mode by pressing the ESC key. - Factory Calibration (CALIB STANDARD). enter the parameter REFERENCE VALUE by pressing RIGHT arrow. confirm the RESET factory with "Y" (yes), with the UP / DOWN arrows 3. Press ENTER to RESET; the output is automatic 30

31 .3. MAINTENANCE (MAINTENANCE) The MAINTENANCE menu is to be used only by qualified and trained personnel, who knows the problems of the inverter control and specific DGBOX characteristics. The menu permits two types of jobs: a) Inspection and routing maintenance jobs b) Configuration of the critical parameters for inverter operation and reset operations PARAMETER SYMBOL SHORT DESCRIPTION 4. SERIAL NUMBER -- DGBOX serial number 4. ALARM HISTORY -- List of alarms during functioning It allows displaying the chronology and type of alarms which have tripped over time, and analysing the operating data at the time of each alarm. An example of the analysis of the parameters during an alarm is shown below. 04//0 5:0 P 0.0 set 4. Bar SYSTEM SET MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE MAIN MENU BASE SETUP ADV SETUP HARDWARE SETUP MAINTENANCE 4 MAINTENANCE SERIAL NUMBER ALARM HISTORY WORKING TIME SET DATA-TIME EXTENDED MENU 4. MAINTENANCE SERIAL NUMBER ALARM HISTORY WORKING TIME SET DATA-TIME EXTENDED MENU 4. ALLARM / // :40:4 08// :7:00 08// :4:4 08// :4:00 CURRENT 08// :08: LIMIT ALARM / // :40:4 08// :7:00 08// :4:4 08// :4:00 08// :08: DRY RUN 08// :7:00 P 3.0 set 3.5 Bar DRY RUN 08// P 3.0 :7:00 set 3.5 Bar 584 Vb 40 C 0:8:37 08// :7:00 P 3.0 set 3.5 Bar 35. HZ 40 V.8 A 3

32 PARAMETER SYMBOL SHORT DESCRIPTION 4.3 WORKING TIME -- Operating statistical data of working pumps It allows displaying the operating time of the selected pump (pump or pump ) and the number of startups made. PARAMETER SYMBOL SHORT DESCRIPTION 4.4 SET DATE-TIME -- Date and time setting menu It permits displaying and changing the date and time. 4.4 TEST - permits performing a FUNCTIONAL TEST of the pumps (both the variable-speed pump and the fixed-speed pump) during first installation or subsequent inspection - The test procedure is automatically interrupted if not operations are performed from the keyboard for over 60 seconds; DGBOX automatically returns to OUT OF SERVICE mode. - To access the TEST mode, place the DGBOX in OUT OF SERVICE mode and then press the TEST key (see fig. below). For model MW30 use the UP/DOWN arrows to select the pum to test (pump or pump ). Variable-speed pump: when the test is started, the pump is supplied at MINIMUM FREQUENCY, to which its performance will be consequently reduced. The only operation which can be carried out is to manually INCREASE and subsequently DECREASE the work frequency (see fig. below) to gradually and reliably determine maximum pump performance. The exit from TEST mode stop the pump () and strike ESC, or strike ESC only; DGBOX will exit from TEST mode and will stop the pump, and then return to OUT OF SERVICE mode. 04//0 5: HZ 40 V 0.0 A START 04//0 5:0 SYSTEM TEST 04//0 TEST 5:0 START 04//0 5:0 TEST 30.0 HZ 40 V.7 A 04//0 P 4. TEST 5:0 3.0 HZ 40 V.8 A.0 Hz.0 Hz 04//0 P 4. 5:0 SYSTEM ESC 04//0 5:0 P 4. TEST START 04//0 5:0 P 4. SYSTEM ESC Fixed-speed pump: to switch to fixed-speed pump, always from TEST mode, press the upward arrow (switch to pump see fig. below); when the test starts, the pump is supplied at 50 Hz. The only operation which can be performed is to SWITCH the pump ON or to determine its performance. 3

33 04//0 5: HZ 40 V 0.0 A START 04//0 5:0 SYSTEM TEST 04//0 5:0 TEST 04//0 TEST 5:0 START 04//0 P 7.6 TEST 5: HZ 40 V A 04//0 5:0 P 4. SYSTEM ESC 04//0 P 4. TEST 5:0 START 04//0 P 4. 5:0 SYSTEM ESC WORK Access to WORK mode is automatic as soon as DGBOX is energised, unless it was manually placed in OUT OF SERVICE mode before the last switch-off. In WORK mode, the operating parameters of the variable-speed pump and of the fixed-speed pump can be displayed (see fig. below), and finally, the option is displayed for placing the single pump in OUT OF SERVICE. If the single pump is in OUT OF SERVICE, the last display shows the START option for returning it to WORK mode // :0 04//0 5: HZ 40 V 5.5 A Vb 49 C 0:05:37? ENTER HZ 40 V 0.0 A? ENTER 5. date. hour 3. pump selection 4. pump operating parameters 5. pump operating parameters 6. working pump (pump ) 7. system pressure fig. 4.4 AUTOMATIC REDUCTION OF THE OPERATING FREQUENCY: if during normal operation overloads occur (current or thermal), DGBOX does not stop the pumps immediately, but automatically reduces the operating frequency until the parameters are returned to their normal values; during this period the displayed frequency flashes, to indicate the fault status. OPERATING PRESSURE QUICK ADJUST: in WORK mode, the work pressure can be quickly changed, without having to access the SET menu; by pressing the ENTER key and, at the same time, the UP or DOWN arrow (depending on whether the pressure is to be increased or decreased), the work pressure is changed with step 0. bar for each strike of the arrow. 33

34 Example: 0. bar set pressure increase (see fig. below). 04//0 5: HZ 40 V.8 A ENTER 04//0 5:0 SET P. set 4. Bar 4. Bar //0 P 4. 5:0 set 4. Bar 37.5 HZ 40 V.9 A 4 OUT OF SERVICE The OUT OF SERVICE mode can involve the entire unit or the single pump. Placing the entire unit out of service: this can be done by manually disabling the system by means of the START/ key. In OUT OF SERVICE mode, the display appears as in fig. 4. below. The return to work mode is manual only, and the OUT OF SERVICE mode is also maintained by switching the system off and back on. The OUT OF SERVICE mode is that suggested to access the CONFIGURATION mode and is necessary to access the TEST mode. Placing the single pump out of service: this can be done by selecting the pump involved (see fig. 4. below, example relating to fixed-speed pump ), scrolling the parameters as far as the option and confirming with ENTER. To place the pump back in service, scroll the parameters as far as the START option and confirm with ENTER. 04//0 a 5: HZ 40 V 0.0 A? ENTER ENTER 04//0 5: HZ 40 V 5.5 A 04//0 5:0 0 4 / / 0 P :0 set 3.5 Bar SYSTEM b START PUMP? ENTER ENTER Fig. 4. fig. 4. if the power supply is interrupted, DGBOX shows a shutdown message : 34

35 5. UPDATE The UPDATE mode permits DGBOX maintenance or software update operations. By means of a standard USB memory, it is in fact possible: - to download the error message history records - to download the set configuration to transfer it to other analogous DGBOX applications - to update the FIRMWARE currently loaded on the power and control boards with others of more recent issue. Operations for accessing the UPDATE mode are:. switch off DGBOX. open the front cover and insert the USB memory (on which there is a FILE recognisable by DGBOX) in the slot provided inside the cable connection area (see picture below) 3. close the front cover again and switch on DGBOX 4. after initialisation, the BOOT LOADER display page appears (see fig. below) BOOT LOADER FIRMWARE UPDATE PARAMETER UP/DOWN HISTORY DOWNLOAD 5. The operation to be performed can be selected: - update the FIRMWARE currently loaded on the power and control boards (FIRMWARE UPDATE) IMPORTANT: DURING FIRMWARE UPDATING, THE POWER SUPPLY TO DGBOX MUST NOT BE INTERRUPTED. - download the set configuration to import it on other DGBOX (PARAMETER UP/DW) - download the error message history records (HISTORY DOWNLOAD) Example : updating firmware with the new PFLMUL.S9 version on the inserted USB memory; at the end of the procedure, if the USB memory is removed, the system starts again. If it is not removed, it returns to the initial display page of the UPDATE mode. 35