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Design Envelope

4300 & 4380


Vertical In-line pumping
unit with ivs drive

Installation and
operating instructions
File No: 101.82iec
Date: january 21, 2019
Supersedes: 101.82iec
Date: august 08, 2018
contents
1.0 introduction 4 4.3.3 about 25
1.1 precautions 4 4.3.4 general settings 26
1.1.1 instructions for safe use 4 4.3.5 manual/auto mode 27
1.1.2 temperature 4 4.3.6 pump control 28
1.1.3 enclosure rating 4 4.3.7 alarms & warnings 31
1.1.4 noise levels 4 4.3.8 trend-graph 32
1.1.5 vibration levels 5 4.3.9 brightness adjustment 32
1.1.6 storage 5 4.3.10 touch screen calibration 33
1.1.7 warranty 5 4.3.11 data logging 34
1.1.8 uncrating 5 4 . 4 web interface 35
1.1.9 handling design envelope 4.4.1 connecting via ethernet 35
4300 & 4380 units 5 4.4.2 connecting via wifi 35
1. 2 mechanical installation 6 4.4.3 switching frequency 35
1.2.1 location 6 4 .5 design envelope flow readout
1.2.2 installation 6 tolerance 36
1.2.3 pump piping – general 7 5.0 control modes 36
1.2.4 alignment 8 5 .1 constant flow 36
2.0 electrical setup 10 5 . 2 constant pressure 36
2.1 remove cover 10 5 .3 linear pressure 36
2. 2 precautions 10 5 . 4 quadratic curve control 36
2.2.1 ground leakage current 11 5 .5 quadratic curve control with
2.2.2 start/stop of pump 11 minimum flow protection 37
2.2.3 additional motor protection 11 5 .6 quadratic curve control with
2.3 electrical installation 11 maximum flow protection 37
2.3.1 supply voltage 11 5 .7 quadr atic curve control with
2.3.2 supply fusing 11 minimum & ma ximum flow protection 37
2.3.3 grounding and it mains 11 5 .8 parallel sensorless
2.3.4 relay connections 13 pump control (pspc) 37
2.3.5 electrical and control connections 14 5 .9 2*100% capacity split units 38
2.3.6 control terminals 15 5 .10 duty-standby mode 38
2. 4 design envelope pump 5 .11 alternation 39
controller wiring 17 6.0 maintenance 39
2.4.1 ethernet and wifi connectivity 17 6.1 general care 39
2.4.2 can bus wiring 17 6. 2 lubrication 39
2.4.3 rs 485 wiring 17 6.3 mechanical seal 40
2.4.4 networking options 17 6.3.1 mechanical seal replacement
3.0 networking controls 18 instructions for 4300 split coupled
vertical in-line pump 40
3 .1 modbus ip & rtu 19
6.3.2 mechanical seal replacement
3 . 2 BACnet ip & ms/ tp 22
instructions for 4380 close coupled
4 .0 operation 24
vertical in-line pump 41
4 .1 start-up checklist 24
7.0 warnings and alarms 44
4 . 2 starting pump 24
7.1 alarm summary for interfaces 44
4.2.1 auto flow balancing 24
7. 2 warning summary for interfaces 45
4 .3 touch screen 25
8.0 fuse and wire recommendation 46
4.3.1 login 25
9.0 pump manager 47
4.3.2 logout 25
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

1.0 introduction 1.1. 2 temper ature


Install the Design Envelope unit with adequate
This manual contains specific information regarding the
access for routine maintenance. A minimum of 2"
safe installation, operation and maintenance of Armstrong
(50 mm) clearance is required at the fan inlet to
Design Envelope pumps. Read this manual carefully before
facilitate airflow. Where several Design Envelope units are
installing or using the product. If clarification is needed on
installed in close proximity, care must be taken to ensure that
any point please contact Armstrong quoting the equipment
there is no re-circulation of exhausted warm air.
serial number.
Under normal operating conditions the pump surface
temperature may reach 68°c/ 155°f (Restricted Zone) to
1.1 precautions 80°c/176°f (Unrestricted Zone). Steps should be taken
1.1.1 instructions for safe use to minimize contact or warn operators/users that normal
operating conditions will be exceeded. In certain cases where
No installation of this equipment should take place
the temperature of the pumped liquid exceeds the above
unless this document has been studied and
stated temperature levels, pump casing temperatures may
understood. Handling, transportation and installa-
exceed 100°c/212°f and not withstanding pump insulation
tion of this equipment should only undertaken by trained
techniques appropriate measures must be taken to minimize
personnel with proper use of lifting equipment. See later
risk for operating personnel. The ambient temperature for
diagrams for lifting advice. Refer to the pump nameplate for
standard motors must be no greater than 40°c/104°f.
pump speed, pressure and temperature limitations. The
limits stated must not be exceeded without written permis-
sion from Armstrong. 1.1.3 enclosure r ating
The standard enclosure rating for Design Envelope
430 0 and Design Envelope 438 0 integrated
controls is ul Type 12 / ipp55 . If the pump is to be
installed in a wet or dusty environment, then a higher
enclosure rating may be required (contact Armstrong).

1.1. 4 noise levels

Typical Pumping Unit Sound Pressure Level, Decibels, A-Weighted, at 1 m (3 ft.) from unit.
1500 rpm 3000 rpm
fr ame fcm tefc fcm tefc
designation
kW db-a kW db-a kW db-a kW db-a

80 0.55-0.75 55 0.55-0.75 47 0.55-0.75 55 0.55-1.1 58


90 1.1-1.5 60 1.1-1.5 49 1.1-1.5 60 1.5-2.2 62
100 2.2 59 2.2 53 2.2 59
100 3 62 3 53 3 62 3 64
112 4 64 4 54 4 63 4 66
132 5.5-7.5 62 5.5-7.5 60 5.5-7.5 62 5.5-7.5 69
160 11-15 63 11-18.5 74
180 18.5-22 65 22 75
200 30 65 30-37 78
225 37-45 66 45 78
250 55 67 55 81
280 75-90 70 75-90 81
315 110-132 78 110-132 82
315 160-200 83 160-200 86
355 250-315 85 250-315 89
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

1.1.5 vibr ation levels


Armstrong Vertical In-Line pumps are designed to meet
vibration levels set by Hydraulic Institute Standard hi Pump
Vibration 9.6.4. Standard levels are as detailed below:

0.4
10

8
Overall Vibration Velocity (mm/s) RMS

0.3

Overall Vibration Velocity (in/s) RMS


7

6
Factory 5.3 mm/s (0.21 in/s) 200 kW (268 bhp) & above
5 Factory 4.3 mm/s (0.17 in/s) below 200 kW (268 bhp) 0.2

4
Field 4.3 mm/s (0.17 in/s) 200 kW (268 bhp) & above
3
Field 3.3 mm/s (0.13 in/s) below 200 kW (268 bhp) 0.1
2
Pump power, bhp
1
10 100 1000
0 0
1 10 100 1000 10000
Pump power, kW

1.1.6 stor age or damage should be reported immediately. Use extreme


Pumps not immediately placed into service, or removed from care in handling the unit, placing slings and hooks carefully
service and stored, must be properly prepared to prevent so that stress will not be imposed on the integrated controls,
excessive rusting. Pump port protection plates must not be pump or motor. Never place cable slings around the pump
removed until the pump is ready to connect to the piping. shaft or integrated controls. The eye bolts or lifting lugs on
the motor are intended for lifting only the motor and not the
Rotate the shaft periodically (at least monthly) to keep rotat- complete unit.
ing element free and bearings fully functional.
For long term storage (longer than three months), the pump 1.1.9 handling design envelope 4300 & 4380 units
must be placed in a vertical position in a dry environment.
To handle Design Envelope 4300 and 4380 units from ship-
Internal rusting can be prevented by removing the plugs at ment, secure the pallet following uncovering the unit, then
the top and bottom of the casing and drain or air blow out all place straps behind the integrated controls (around the mo-
water to prevent rust buildup or the possibility of freezing. Be tor feet) and carefully lift the pumping unit to stand the pump
sure to reinstall the plugs when the unit is made operational. vertically upright.  Lift only sufficiently to remove the pallet,
Rustproofing or packing the casing with moisture absorb- then lower onto a flat surface. The pump and motor unit will
ing material and covering the flanges is acceptable. When free-stand on the casing ribs. Extra care is required to ensure
returning to service be sure to remove the drying agent from the integrated controls do not get damaged during lifting and
the pump. installation.

1.1.7 warr ant y


Armstrong’s warranty period for Design Envelope pumps
is [ 18] months from date of shipment, or [ 12] months from
date of installation, whichever comes first. Please refer to
File 9 .10us / 9 .10c for full terms and conditions. To receive
an additional [6] months of standard coverage, owner may
register the pump unit at
www.armstrongfluidtechnology.com/warrantyregistration

1.1.8 uncr ating For Design Envelope 4300 units, remove the coupling guard
Armstrong Vertical In-Line pumps are thoroughly inspected and insert lifting straps through the pump/motor pedestal
before shipment to assure they meet with your order require- on either side of the coupling. For Design Envelope 4380
ments. After removing the pump from the packaging, make units, remove the motor eye-bolt and install a swivel hoist
sure the equipment is in good order and that all components ring tied to a lifting strap. Place secondary lifting straps
are received as called for on the packing list. Any shortages around the motor feet (and/or spacers). As the lifting device
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

is engaged (Using a spacer bar if necessary) and the straps supplied with integral disconnect switches, 36"/1 meter
tighten ensure no part of the strapping is touching any part clearance may be required in front of the controls to meet
of the control or motor fan cover. Lift the pumping unit local electrical codes.
carefully from the pallet in this manner and allow the unit to
stand upright on a flat surface and re-position the straps, if
1. 2 . 2 installation
necessary, to ensure safe and damage-free transportation
When installing vertical in-line pumps, an important
into the pipe installation.
consideration to accrue full added-value from the pump
design is to ensure that the pump is pipe-mounted and free
to ‘float’ with any movement, expansion and contraction of
the piping. Should any vertical in-line pump use supports to
the structure it is imperative that no pipe strain is imposed
on the pump flanges. Tell-tale pieces of equipment such as
springs or ‘waffle’ style neoprene isolation pads that distort
with pressure to indicate added piping weight, should be
used under pump supports should the pump not be truly
4300 4380 pipe mounted.

Remove coupling guard and Remove the motor eye-bolt and Design Envelope 430 0 and Design Envelope 438 0 cannot
place lifting straps on each side install a swivel hoist ring tied to a be mounted with shafts in the horizontal position.
of coupling, use spacer bar if nec- lifting strap. Place secondary lift-
essary to protect the integrated ing straps securely around motor Various installation arrangements are detailed on Pages
controls and motor fan cover. feet (and/or spacers). 8 –10
a
important: Vertical In-Line pumps may be installed directly in the sys-
tem piping with no additional support. Pipe hangers are sim-
Do not run the pump for any length of time under ply sized for the additional weight of the pumping unit. Many
very low flow conditions or with the discharge valve pumps are installed in this manner and can be mounted at
closed. To do so could cause the water in the casing sufficient height to take zero floor space. (fig . 1.1)
to reach super heated steam conditions and will cause
premature failure and could cause serious and dramatic b
damage to the pump and surrounding area. Piping in many mechanical rooms is hung close to the ceiling
and larger pumps are mounted near ground level for ease of
maintenance. fig . 1. 2 illustrates such an arrangement with
the piping supported at the ceiling and the vil unit installed
1. 2 mechanical installation with an Armstrong Suction Guide and Flo-Trex valve. Many
1. 2 .1 location very large vil pumps are installed in this manner.
In open systems, locate the unit as close as practical to the c
liquid being pumped, with a short, direct suction pipe. Ensure Should additional space saving be required the discharge
adequate space is left above and around the unit for opera- spool piece may be replaced by a long-radius elbow.
tion, maintenance, service and inspection of parts.
d
In closed systems, where possible, the pumps should be fig 1. 4 illustrates a similar arrangement to fig . 1. 2 with
installed immediately downstream of the expansion tank / additional floor mounted pipe-stools isolated from the
make-up connection. This is the point of zero pressure change structure by ‘waffle’ style neoprene isolation pads under the
and is necessary for effective pump operation. Do not install Armstrong Suction Guide and Flo-Trex valve.
more than one expansion tank connection into any closed
e
hydronic system.
Floor mounted saddle supports (fig . 1.5) are typical for
Electric motor driven pumps should not be located in damp condenser water pumps where cooling tower base is at the
or dusty location without special protection. mechanical room elevation.
Airflow into the motor and/or motor fan should not be ob- f
structed.
Where required, additional floor support may be used as
It is good practice to leave sufficient space around equipment shown in fig . 1.6. Note that the pump should not be rigidly
for maintenance and service needs. If the ivs controls are attached to the column. Leave a small gap between pump
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

and column or install a waffle isolation pad under the pump. m


It is critical that piping be installed in such a manner that the For d1 and d2 chassis ivs units (150 hp–350 hp), ensure ad-
pump does not become a pipe support. equate space is available for the access door to swing open.
g (fig . 1.13)
fig . 1.7 illustrates stanchion plates at the pump inlet and
outlet ports that may be supplied for installation conve- important:
nience. Isolation pads must be used under the legs and All Design Envelope 4300 pumps contain a tapped hole in
monitored as pipe hangers are adjusted to ensure the pump the motor bracket above the discharge flange (see Fig. fig .
flanges are not supporting the piping. Bolting to the floor or 1.14) for draining the well. Pipe this drain hole to a floor drain
housekeeping pad is not recommended. If the stanchions are to avoid overflow of the cavity caused by collecting chilled
bolted down the bolts must be isolated from the stanchion or water condensate or from seal failure.
an inertia base and flexible pipe connectors used.
h 1. 2 .3 pump piping – gener al
fig . 1. 8 illustrates installations with stanchion plates for
Never connect a pump to piping, unless extra care is taken
seismically active regions. Seismically rated isolation pads
to measure and align the piping flanges well. Always start
or snubbers with bolts isolated from the stanchion plates are
piping from pump.
installed to restrain the pump during a seismic event. Pipe
hangers carry the weight of the equipment as seismic com- Use as few bends as possible and preferably long radius
ponents are designed only to restrain the equipment during a elbows.
seismic event. Do not use flexible connectors on the suction or discharge of
i a vertical in-line pump, unless the pump is rigidly mounted to
a foundation.
Many Vertical In-Line pumps are piped successfully into
grooved piping systems. In-line pumps are supported well Ensure piping exerts no strain on pump as this could distort
by grooved piping however flange adapter locking devices the casing causing breakage or early failure due to pump
or a welded flange at the pump should be used to prevent misalignment.
the possibility of pipe mounted pumps rotating in the piping. All connecting pipe flanges must be square to the pipe work
Armstrong offers grooved suction guides with cast-in outlet and parallel to the pump flanges.
flanges and Flo-Trex valves with Armgrip™ fittings to prevent
Suction and discharge pipes may be increased or decreased
this possibility. (fig . 1.9)
at pump nozzle to suit pump capacity and particular condi-
j tions of installation. Use eccentric reducers on suction con-
Do not support the unit by the motor eye bolts (fig . 1.10) or nection with flat side uppermost.
by any other part of the motor.
Layout the suction line with a continual rise towards the pump
k without high points, thus eliminating possibility of air pockets
Connecting the pump to a permanent rigid base (fig . 1.11) is that may prevent the pump from operating effectively.
not recommended unless isolated from the piping by flexible
A strainer of three or four times the area of the suction pipe,
connectors and the base isolated from the building structure
installed in the suction line, will prevent the entrance of for-
on an inertia base. (fig . 1.11 is generally acceptable when
eign materials into the pump. V" (3 mm) diameter perfora-
using plastic piping).
tions in the strainer is typical.
l
In open systems, test suction line for air leaks before starting;
The motor and integrated control assembly can be rotated this becomes essential with long suction line or static lift.
in 90° increments to meet installation spacing requirements. 
Install, at the pump suction, a straight pipe of a length
Where applicable, remove the coupling guard to access the
equivalent to four or six times its diameter; this becomes es-
motor bolts. Remove the motor bolts to rotate the motor and
sential when handling liquids above 120°f (49°c). Armstrong
integrated control assembly by hand. Larger motors may
suction guides may be used in place of the straight pipe run
need strapping and slight lifting to break the contact with the
and in-line strainer.
pedestal. Care should be taken that the controls are not dam-
aged during lifting and that the flushline, accessories and the Install an isolation valve in both suction and discharge lines
coupling guard removal/seal service window are not com- on flooded suction application; these valves are used primar-
promised following the turn (fig . 1.12). vil pumping units ily to isolate the pump for inspection or repair.
without integrated controls can also be rotated in a similar
manner to facilitate access to the the motor terminal box.
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

Install a non-slam non-return check valve in discharge line fig . 1.3 Discharge elbow for minimum footprint
between pump and isolation valve to protect pump from
Hangers support the weight
excessive back pressure and to prevent water running back of the filled piping, pumps
Pipe hanger (typ.)
see specification for
and fittings
through the pump in case of driver failure on open systems. size and type

1. 2 . 4 alignment System inlet System outlet

Design Envelope 4300 units are accurately aligned Split coupler


at the factory prior to being shipped and do not Flush line

need re-aligning when installed. Recommended field


Flo-Trex valve
pressure gauge
Alignment on a Design Envelope 4300 unit may be verified by piping arrangement

assuring an equal and parallel gap between coupling halves


on both sides of the coupling. Suction guide

Drain connection
fig . 1.1 Hanger supported pipe mounted
fig . 1. 4 With additional pipe supports

Hangers support the Pipe hanger (typ.)


weight of the filled piping, see specification for
pumps and fittings size and type

System inlet System outlet

Split
coupler

Recommended field
pressure gauge piping Flush line
arrangement Flo-Trex valve
Pet cock
Suction guide
(typ.)

Pipe support
2" or 3"
height above
fig . 1. 2 Pipe mounted supported at ceiling Neoprene
isolation pad
Drain connection finished floor

Hangers support the weight Pipe hanger (typ.)


of the filled piping, pumps see specification
and fittings for size and type fig . 1.5 Floor saddle support

System inlet System outlet

Split
coupler

Recommended field
pressure gauge piping Flush line
arrangement
Flo-Trex valve
Suction guide Pet cock
(typ.)

2" or 3"
height above
Drain connection finished floor
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

fig. 1.6 Additional floor support fig . 1.9 Mounting in grooved pipe systems

Hangers support the weight of the Pipe hanger


filled piping, pumps and fittings (typ.) See
specification for
size and type

System inlet System outlet


7700 butterfly Gruvlok 7000 flex
valve coupling (typ.)
Split
coupler
Recommended field Flush line
pressure gauge
piping arrangement Flo-Trex valve
Pet cock
(typ.)
Suction guide

Drain connection
GAP

fig . 1.10 Motor lifting hook supported

fig . 1.7 With stanchion plates

fig . 1.11 Mounted on rigid base without flexible connectors

Stanchion plates

Isolation Pads

fig . 1. 8 Seismic region installation

fig . 1.12 Motor and integrated controls assembly can be


rotated in 9 0° increments to meet installation
spacing requirements

Stanchion plates

Seismically rated snubbers or pads and


conrete foundation
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

10

fig . 1.13 Clearance radius for d size chassis For d1 and d2 chassis ivs units, access door swings open (see
fig . 1.13). When replacing the front cover, please ensure
proper fastening by applying a torque of 2Nm.
29.5"typ

15.7
(399)

≤105,0
o

20.7
(526)

fig . 1.14 Tapped collection well on Design Envelope 430 0

do not
pry
from
sides
Design Envelope 4300
seal leaks or condensate
drain hole. Plumb to drain
for area cleanliness.
do do
not not
pry pry

fig . 1.15 Clearance note

1 m (36") clearance in
front of controls may be
2. 2 precautions
required in your locale The standard enclosure rating for Design Envelope
4300 and Design Envelope 4380 integrated
controls is ul type 12 or ul type 4x for outdoor
applications. If the pump is to be installed in a wet
or dusty environment then a higher enclosure
rating may be required (contact Armstrong).
To avoid the inverter unit getting overheated, the
ambient temperature is not to exceed 133°f (45°c)
average daily temperature. Operating in higher
ambient temperatures will require derating of the
inverter.
2.0 electrical setup
All electrical connections should be carried out by
2.1 remove cover a qualified and authorised electrician in accor-
Remove front cover to access mains and grounding connec- dance with local site regulations and the latest
tions, and control terminals. Carefully lift the cover from the issue of the iee regulations.
bottom edge to remove. do not pry the cover open from
the side edges.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

11

Before removing the inverter cover, the system over-temperature protection is required (i.e.
must be disconnected from the mains supply. After thermal overloads). Protection features include:
switching off, wait for at least 15 minutes for the • Mains phase loss
capacitors to discharge before opening the cover.
• Over voltage
caution • Under voltage
High voltage testing (Megging) of the motor/ • Electronic thermal motor protection
inverter may cause damage to the electronic • Short circuit on motor terminals
components and therefore should not be carried out. • Ground fault on motor terminals
• Over temperature
2 . 2 .1 ground leak age current
Ground leakage current is primarily caused by the
capacitance between motor phases and the motor 2.3 electrical installation
frame. The rfi filter contributes additional leakage 2 .3 .1 supply voltage
current, as the filter circuit is connected to ground The supply voltage details can be found on the ivs name-
through capacitors. plate. Please ensure that the unit is suitable for the electrical
The size of the leakage current to the ground depends on the supply on which it is to be used. The mains supply for Design
following factors, in order of priority: Envelope pumps is as follows:
1 Switching frequency 1 × 2 0 0 -24 0v ± 10 %
2 Motor grounded on site or not 3 × 2 0 0 -24 0v ± 10 %
The leakage current is of importance to safety during han- 3 × 3 8 0 - 4 8 0v ± 10 %
dling/operation of the Design Envelope pump if (by mistake) 3 × 525 - 6 0 0v ± 10 %
the on-board inverter has not been grounded. Supply frequency — 50/6 0Hz
Since the leakage current is >3 .5ma (approx
4-20ma), reinforced Grounding must be estab- 2 .3 . 2 supply fusing
lished which is required if en 50178 is to be
Branch circuit protection
complied with. Never use elcb relays that are not
suitable for dc fault currents (type a). In order to protect the installation against electrical and fire
hazard, all branch circuits in an installation, switch gear, ma-
If elcb relays are used, they must be:
chines etc., must be short-circuit and over-current protected
• Suitable for protecting equipment with a direct current con- according to the national/international regulations.
tent (dc) in the fault current (three-phase bridge rectifier)
• Suitable for power-up with short charging current to Short circuit protection
Ground The inverter must be protected against short-circuit to avoid
• Suitable for a high leakage current electrical or fire hazard. Armstrong recommends using the
fuses detailed in the separate ivs Operating Instructions to
protect service personnel or other equipment in case of an
2 . 2 . 2 start/stop of pump
internal failure in the unit. The frequency converter provides
The number of starts/stops via the mains voltage must not full short circuit protection in case of a short-circuit on the
exceed one-time per minute. motor output.
If a higher number of starts/stops is required then the start/
stop digital input must be used (mains voltage directly con-
2 .3 .3 grounding and it mains
nected). This is the preferred method of starting and stop-
The ground connection cable cross section must be
ping Design Envelope Pumps.
at least 10 mm2 or two rated mains wires termi-
The three phase mains must be isolated before performing nated separately according to en 50178 or iec
maintenance of the pump. 618 0 0 - 5-1 unless national regulations specify
differently. Always comply with national and local
2 . 2 .3 additional motor protection regulations on cable cross sections.
With the exception of supply fuses / mcb’s to
The mains is connected to the main disconnect
protect the installation (for over-current and
switch if this has been included.
short-circuit protection), no additional overload or
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s
4.6 GROUNDING AND IT MAINS In-line pumping unit with ivs drive

The ground connection cable cross section must be at


12 least 10 mm 2 or 2 rated mains wires terminated sepa-
5 How totoInstall
rately according EN 50178 or IEC 61800-5-1 unless national VLT® AQUA Drive Design Guide
regulations specify differently. Always comply with national and
local regulations on cable cross sections.
2. Place plug connector 91, 92, 93 from the accessory bag onto the terminals labelled MAINS at the bottom of the frequency converter.
Checkisthe mains voltage corresponds fig . 2 .3a Mains and grounding connections for b1 and b2
The mains connected to the main disconnectto the mains
switch
3. Connect mains wires to the mains plug connector. units (20 0 -2 40V95
- 2 to 7.5hp 1ph/ 7.5 to 20hp
if thisvoltage of included.
has been the frequency converter name plate.
3ph, 38 0 -48 0V - 15 to 40hp, 5 25- 600V – 15
NB! to 50hp)
Do The
notearth
Check the mains
connect
voltage
frequency
corresponds
connection
converters
to themust
cable cross section mains
with rfi-
be atvolt-
least 10 mm2 or 2 rated mains wires terminated separately according to EN 50178.
filters
age of the to mains
frequency convsupplies with plate.
erter name a voltage between
phase and ground of more than 4 40 v for 400 v
IT Mains
converters and 760 v for 690 v converters. For 400
Do connection
The mains not connect frequency
is fitted converters
to the main with
switch if this RFI-filters to
is included.
mainsv supplies
it mainswith andadelta
voltageearth (grounded
between phase andleg), mains
earth of morevoltage
than 440may V forexceed 4 40 v between phase
400 V converters and 760 V for and 95
690 V converters. For 400 V IT mains and delta earth
earth. For 690 v it mains and delta earth (ground-
(grounded leg), mains
NB! voltage may exceed 440 V between
ed leg),
phase and earth. For 690
Check
mains
thatVmains
voltage
IT mains and
voltage
may
deltaexceed
correspondsearth 760 v between
to the mains voltage of the frequency converter name plate.
phase
(grounded leg), mainsand earth.
voltage may exceed 760 V between
5 phase and earth.
fig . 2 .1 Terminals for mains and grounding
IT Mains
Do not connect 400 V frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than
3 phase
440 V.
power input Figure 4a. Mains and Grounding Connections for B1 and B2
For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth.
Units (200-240V - 7.5 to 20HP, 380-480V - 15 to 40HP, 525-
600V - 15 to 50HP)

fig . 2 .3b Mains and grounding con-


Figure 2. Terminals for Mains and Grounding nections for c 1 and c2 units 91 92 93
L1 L2 L3
(20 0 -2 40V – 25 to 6 0hp,
1 phase 95
38 0 -48 0V – 50 91
to 125hp,
92 93
power input L1 to 125hp)
5 25- 6 0 0V – 6 0 L2 L3

95
Illustration : Terminals for mains and earthing.
95

fig . 2 . 2 Mains and grounding connections for a5 units


(20 0 -2 40V - 1.5hp 1ph/5hp and below 3ph,
38 0 -48 0V/5 25- 6 0 0V - 10hp and below)

95
fig . 2 .3c Mains and grounding connections for d1 and d2
units ( 38 0 -48 0v – 150 to 350hp, 5 25- 6 0 0v–
150 to 350hp)

95

Figure 3. Mains and Grounding Connections for A5 Units Figure 4b. Mains and Grounding Connections for C1 and C2
(200-240V - 5HP and Below, 380-480V / 525-600V - 10HP units (200-240V - 25 to 60HP, 380-480V - 50 to 125HP, 525-
and Below) 600V - 60 to 125HP)

Page 10 of 26

122 MG.20.N5.02 - VLT® is a registered Danfoss trademark


Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

13

2 .3 . 4 relay connections fi g . 2 .6 Relay connection terminals for c 1 and c2 units


The relays on the ivs are configured as follows:
Relay 1 – alarm
• Terminal 01: Common
• Terminal 02: Normal Open 240v ac
• Terminal 03: Normal Closed 240v ac

Relay 2 – run status


• Terminal 04: Common
• Terminal 05: Normal Open 400v ac
• Terminal 06: Normal Closed 240v ac

fig . 2 . 4 Relay contact details

fig . 2 .7 Relay connection terminals for c 1 and c2 units

The following illustrations identify the location of the relays


within specific inverter sizes:
AUX RELAY
The illustrations in figures 6, 7 and 8 identify the location of 01
04
02
05
03
06

the relays within specific inverter sizes:

fig . 2 .5 Relay connection: terminals for a5 , b1 and b2 units


i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

14

2 .3 .5 electrical and control connections


fig . 2 . 8 Diagram showing all electrical connections
*Note: Terminal 37 is not available on Design Envelope pumps

3-Phase Power
input (1-ph
power: No 92 (l2)
connection)

Reserved for control module


Remove front-cover to access control terminals. For D1 and 42 Analogue Output Output Frequency
D2 chassis18
IVS units accessDigital
swings open. (see Fig.Start
Input 2.13) . (4-20mA - 0-100Hz)
When replacing the front cover, please ensure proper fasten- 53 Analogue Input Reference (0-10V)*
ing by applying
19 a torque ofDigital
2 Nm. Input Pump Operating Mode
54 Analogue Input Feedback (0-10V)*
4.8.2 CONTROL
20 Design
TERMINALS
Common Envelope
0V 4300 & 4380 Vertical i nsta l l a ti o n &
With reference
27 to figure 10: In-line pumping
Digital Input unit with*Note
Low Water Interlock ivs that
drive o perati
Analogue inputs ngAI54
AI53 and i nstr
can beucti o ns
either Volt-
age (0-10V) or Current (4-20mA) input and by default both
Figure 10.29Control Connections
Digital Input No Operation inputs are set to Voltage.
Switches S201 and S202 (see figure 9) are used to configure
32 Digital Input No Operation the analogue inputs as follows: 15
33 Digital Input No Operation S201 (AI53) OFF = Voltage, ON = Current
S202 (AI54) OFF = Voltage, ON = Current
37 Digital Input No Operation
Inserting Cables into Control Terminals
2 .3 .6 control terminals
Remove front-cover to access control terminals. For D1 and
D2 chassis IVS units access swings open. (see Fig. 2.13) .
42 Analogue Output Output Frequency
(4-20mA - 0-100Hz) i) Strip 10mm of insulation from the cable:
When replacing the front cover, please ensure proper fasten- Inserting Cables into Control Terminals
ing by applyingWith reference to figure 10: 53 Analogue Input Reference (0-10V)*
a torque of 2 Nm. ii) Insert a suitable terminal screwdriver as
figTERMINALS
4.8.2 CONTROL . 2 .9 Control Connections 54 Analogue Input i Feedback
Strip(0-10V)*
10mm ofshown
insulation
and thenfrom the
push the cable:
cable into the terminal.

for inputiiand
Insert a suitable terminal screwdriver
With reference to figure 10: *Note that Analogue inputs AI53 and AI54 can be either Volt-Iii) Remove the terminal screwdriver and
1 10-way
age (0-10V) plug
or Current (4-20mA) by default both check the terminal has gripped the cable
Figure 10. Control Connections digital i/0
inputs are set to Voltage. as shown and by then push
gently pullingthe
it. cable into
Switches S201 and S202 (see figure 9) are used to configure
the analogue inputs as follows: the terminal. Note: Terminal plugs can be easily re-
2 3-way plug for moved for improved access when making
S201 (AI53) OFF =
rs485 iii Remove the terminal
Voltage, ON = Current
bus connections. screwdriver and
S202 (AI54) OFF = Voltage, ON = Current
check the terminal has gripped the cable
3 6-way
Inserting plug
Cables into forTerminals
Control
by gently pulling it.
1. 10 wayi) plug analog
Strip for
10mmdigital i/0 from the cable:
I/O
of insulation
2. 3 way plug for RS485 Bus
ii) Insert a suitable terminal screwdriver as
3. 6 way shown
plug forand then push
analogue Note:
I/O the cable into the Terminal
terminal.plugs can be easily removed for improved ac-
4. USB Connection cess
Iii) Remove the terminal screwdriver and when making connections.
check the terminal has gripped the cable
by gently pulling it. Page 14 of 26

Note: Terminal plugs can be easily re-


moved for improved access when making
connections.

1. 10 way plugFor connection


for digital I/O to external devices such as start / stop
2. 3 way plug switches,
for RS485 Bus differential pressure sensors, or temperature
3. 6 way plug sensors
for analogueetc.,
I/O refer to the following wiring instructions to the
4. USB Connection
terminals and webserver configuration screens.
Page 14 of 26
webserver
terminal t ype / factory
configur ation
no. description set ting
ref
1, 2, 3 Relay 1 Alarm G
4, 5, 6 Relay 2 Run Status G
18 Digital Input 1 Start / Stop A
19 Digital Input 2 Start / Stop B
Alarm, Flow
Threshold, Head
27 Digital Output 1 E
Threshold,
Run Status
Alarm, Flow
Digital Threshold, Head
29 F
Output 2 Threshold,
Run Status
42 Analog Output Speed
Speed Control,
53 Analog Input 1 C
Pressure Sensor
Speed Control,
54 Analog Input 2 D
Pressure Sensor

*Note that Analogue inputs ai53 and ai54 can be either Volt-
age (0-10v) or Current (4-20ma) input and by default both
inputs are set to Voltage. Switches s201 and s202 (see figure
9) are used to configure the analogue inputs as follows:
s201 (ai53) off = Voltage, on = Current
s202 (ai54) off = Voltage, on = Current
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

16

webserver configur ation

Select Pump in the left side-menu

For Digital Inputs (A, B) that have been wired: For Digital Functions (E, F) that have been wired:
1 Select On/Off, then 1 Select Enabled, then
2 Select Update 2 S
elect one of Alarm, Flow Threshold, Head Threshold,
or Run Status

For Analog Inputs (C, D) that have been wired: 3 Enter the threshold value in the text box (as applicable),
4 Select Update
1 Select Speed or Pressure, for the control type
2 Select Current or Voltage,
3 Enter values in the text box (as applicable), For Digital Inputs (G) that have been wired:

4 Select Update 1 Select Enabled, then


2 Select Alarm or Run Status,
3 Select Update
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

17

2. 4 design envelope pump con- Enabled, (towards the en label for the bas ports). If multiple pumps
troller wiring are connected in parallel for can bus (supplied by others) they should
fig . 2 .10 Controller Board be daisy chained together. Ensure that only the first and last terminat-
ing resistor switches are set to Enabled.

2.4.3 rs 485 wiring


For Modbus rtu or BACNet ms/tp connection to building automa-
Modbus
tion system, connect rs485 cable to this port per fig. 2.10. If the
depc is connected to the bas, ensure that the terminating resistor
CAN bus switch is set to Enabled (towards the en label for the bas ports).
If multiple pumps are connected in parallel to the bas, the bas wiring
(supplied by others) should be daisy chained together. Ensure that
only the first and last terminating resistor switches are set to Enabled.
See example below in fig 2.10.1
fig. 2.10.1
ba ba ba
fig . 2 .10a Controller Board ba
g g g
g

A = + Positive A = + Positive A = + Positive A = + Positive


B = - Negative B = - Negative B = - Negative B = - Negative
G = Ground G = Ground G = Ground G = Ground

A = + Positive
B = - Negative
G = Ground

pump controller 1 pump controller 2 pump controller 3 pump controller 4

2 . 4 . 4 networking options
fig. 2.11

bms

rs-485

6.1

bms

6.2
2.4.1 ethernet and wifi connectivity
For BACNet tcp/ip connection to building automa-
tion system, connect connect r j-45 cable to this
port per fig. 2 .10

2.4.2 can bus wiring


Connections, Low, High, and Ground as per fig.
2.10. If the depc requires a can bus connection,
ensure that the terminating resistor switch is set to
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

18

3 .0 networking controls
For connection to the building automation system (ba s),
the pump needs to be properly configured to the network.
Ensure the r s485 cable is connected to the controller board
(fig.2 .10). Or if connecting to the bas via router, ensure that
the r j-45 cable is connected to the controller board (fig.
2 .10 ).

The pump controls can be configured from the touchscreen


or the webserver.

For BACNet ms/ tp or tcp/ip: Enter the BACNet address,


baud rate, and unique device instance number (as applicable)
For Modbus rtu or tcp/ip: Enter the Modbus address, baud
rate, and parity stop bits (as applicable)
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

19

3 .1 modbus ip & rtu


function code
change
modbus # of data
read write start address descrip tion during unit notes
register registers t ype
operation
0×01 0×03 0×05 0×06

Status
The current speed of the vfd
x 10 0 101 Actual speed 1 n/a uint16 1 rpm
in rpm.
The current speed of the vfd
x 101 102 Actual speed 1 n/a uint16 0.1 % in % of the nominal motor
speed.
Motor input Units as configured on pump
x 102 103 2 n/a uint32 0.01
power control module.
Motor input Voltage delivered by the vsd
x 104 105 1 n/a uint16 0.1 V
voltage to the motor.
Motor input Current delivered by the vsd
x 105 10 6 2 n/a uint32 0.01 A
current to the motor.
Sensorless Units as configured on pump
x 107 10 8 2 n/a uint32 0.01
head control module.
Sensorless Units as configured on pump
x 109 110 2 n/a uint32 0.01
flow control module.
Used for parallel sensorless
x 111 112 Total flow 2 n/a uint32 0.01
mode
Used for parallel sensorless
x 113 114 Total power 2 n/a uint32 0.01
mode
Number of
Used for parallel sensorless
x 115 116 running 1 n/a uint16 —
mode
pumps
Max sensor- Units as configured on pump
x 116 117 2 n/a uint32 0.01
less flow control module.
Max sensor- Units as configured on pump
x 118 119 2 n/a uint32 0.01
less head control module.
x 120 121 btu/h 2 n/a uint32 — Not implemented
i/o
Digital input 1 is bit 0 and
x 200 201 Digital in 1 n/a uint16 —
input 2 is bit 1.
0.01
Units as configured on Pump
x 201 202 Analog in 1 2 n/a uint32 V, 0.01
Control Module
mA
0.01
Units as configured on Pump
x 203 204 Analog in 2 2 n/a uint32 V, 0.01
Control Module
mA
x 205 206 Analog Out 1 1 n/a uint16 0.01 mA
Digital output 1 is bit 0 and
x 206 207 Digital Out 1 n/a uint16 —
output 2 is bit 1.
Relay 1 is bit 0 and relay 2 is
x 207 208 Relays 1 n/a uint16 —
bit 1.
Units
1 = l/s; 2 = m3/h;
x 250 251 Flow units 1 n/a uint16 —
3 = g/m
1 = bar; 2 = kPa;
x 251 252 Pressure units 1 n/a uint16 —
3 = psi; 4 = ft; 5 = m
x 252 253 Power units 1 n/a uint16 — 1 = kW; 2 = hp
x 253 254 Speed units 1 n/a uint16 — 1 = rpm; 2 = %
Temperature
x 254 255 1 n/a uint16 — 1 = °c; 2 = °f
units
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

20

function code
change
modbus # of data
read write start address descrip tion during unit notes
register registers t ype
operation
0×01 0×03 0×05 0×06

Counters
Total pump
x 275 276 2 n/a uint32 1h
running hours
Trip pump Writing 0 to this register
x x 277 278 2 n/a uint32 1h
running hours resets the counter.
Total
x 279 280 controller 2 n/a uint32 1h
running hours
Present
The running hours since the
x 281 282 controller 2 n/a uint32 1h
controller was powered on.
running hours
Total pump
x 283 284 running kWh 2 n/a uint32 1 kWh
counter
Trip pump
Writing 0 to this register rests
x x 285 286 running kWh 2 n/a uint32 1 kWh
the counter.
counter
Total btu
x 287 288 2 n/a uint32 — Not implemented
counter
Trip btu
x x 289 290 2 n/a uint32 — Not implemented
counter
Control Settings
1 = Parallel
2 = i/o
3 = Remote
4 = Constant flow
5 = Constant pressure
x 300 301 Control mode 1 Yes uint16 — 6 = Linear pressure
7 = Quadratic pressure
8 = Quad pressure max.
9 = Quad pressure min.
10 = Quadratic
pressure max/min
0 = Off
x x 301 302 hoa state 1 Yes uint16 — 1 = Hand
2 = Auto
1 = standard
Active
x x 302 303 1 Yes uint16 — 2 = mode 1 (heating mode)
parameters
3 = mode 2 (cooling mode)
Minimum Units as configured on pump
x x 303 304 1 Yes uint16 0.1
speed limit control module.
Maximum Units as configured on pump
x x 304 305 1 Yes uint16 0.1
speed limit control module.
Hand mode Units as configured on pump
x x 305 306 1 Yes uint16 0.1
speed control module.
bms set Units as configured on pump
x x 306 307 1 Yes uint16 0.1
speed control module.
Alarms and Warnings
Refer to alarms table for bit
x 400 401 Alarms 2 n/a uint32 —
positions
Refer to alarms table for bit
x 402 403 Warnings 2 n/a uint32 —
positions
Acknowledge 32-bit field corresponding to
x x 404 405 2 Yes uint32 —
Warnings the warning field
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

21

function code
change
modbus # of data
read write start address descrip tion during unit notes
register registers t ype
operation
0×01 0×03 0×05 0×06

Parameters
Value for standard active
Standard
mode. Units as configured on
x (x) 500 501 mode – zero 2 Yes uint32 0.01
Pump Control Module. (Key
flow head
required to write.)
Value for standard active
Standard
mode. Units as configured on
x (x) 502 503 mode – design 2 Yes uint32 0.01
Pump Control Module. (Key
head
required to write.)
Value for standard active
Standard
mode. Units as configured on
x (x) 504 505 mode – design 2 Yes uint32 0.01
Pump Control Module. (Key
flow
required to write.)
Value for standard active
Standard
mode. Units as configured on
x (x) 506 507 mode – 2 Yes uint32 0.01
Pump Control Module. (Key
minimum flow
required to write.)
Value for active mode 1. Units
Mode 1 – zero as configured on Pump Con-
x (x) 508 509 2 Yes uint32 0.01
flow head trol Module. (Key required to
write.)
Value for active mode 1. Units
Mode 1 – as configured on Pump Con-
x (x) 510 511 2 Yes uint32 0.01
design head trol Module. (Key required to
write.)
Value for active mode 1. Units
Mode 1 – as configured on Pump Con-
x (x) 512 513 2 Yes uint32 0.01
design flow trol Module. (Key required to
write.)
Value for active mode 1. Units
Mode 1 – as configured on Pump Con-
x (x) 514 515 2 Yes uint32 0.01
minimum flow trol Module. (Key required to
write.)
Value for active mode 2. Units
Mode 2 – zero as configured on Pump Con-
x (x) 516 517 2 Yes uint32 0.01
flow head trol Module. (Key required to
write.)
Value for active mode 2. Units
Mode 2 – as configured on Pump Con-
x (x) 518 519 2 Yes uint32 0.01
design head trol Module. (Key required to
write.)
Value for active mode 2. Units
Mode 2 – as configured on Pump Con-
x (x) 520 521 2 Yes uint32 0.01
design flow trol Module. (Key required to
write.)
Value for active mode 2. Units
Mode 2 – as configured on Pump Con-
x (x) 522 523 2 Yes uint32 0.01
minimum flow trol Module. (Key required to
write.)
Information
Pump name / The pump name as a series of
x 900 901 8 n/a ascii —
tag name a scii characters.
Serial no. Of the pump
x 908 909 Serial number 7 n/a ascii — represented by a scii
characters
Divide the number by 1 0 0 to
Firmware
x 915 916 1 n/a uint16 00.00 get the major. Minor version
version
of the depc.
Hardware The pump control module
x 916 917 1 n/a uint16 —
version hardware version.
Modbus Version of the Armstrong
x 917 918 1 n/a uint16 —
version Modbus version
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

22

3 . 2 BACnet ip & ms/ tp


object id object name read/ write comments
Status
av: 1 0 0 Actual speed Read in rpm
av: 1 0 1 Actual speed Read in %
av: 1 02 Motor input power Read Unit as configured in pump control module
av: 1 03 Motor input voltage Read in volts
av: 1 04 Motor input current Read in amps
av: 1 0 5 Sensorless head Read Unit as configured in pump control module
av: 1 0 6 Sensorless flow Read Unit as configured in pump control module
av: 1 07 Total flow Read Used for parallel sensorless mode
av: 1 0 8 Total power Read Used for parallel sensorless mode
av: 1 0 9 No. of running pumps Read Used for parallel sensorless mode
av: 11 0 Max sensorless flow Read Unit as configured in pump control module
av: 111 Max sensorless head Read Unit as configured in pump control module
av: 112 btu/h Read Not implemented
Counters
av:2 75 Total pump running hours Read
av:2 76 Trip pump running hours Read/Write Writing 0 to this register resets the counter.
av:2 7 7 Total controller running hours Read
av:2 78 Present controller running hours Read The running hours since the controller was powered on.
av:2 79 Total pump running kwh counter Read
av:28 0 Trip pump running kwh counter Read/Write Writing 0 to this register resets the counter.
av:28 1 Total btu counter Read Not implemented
av:282 Trip btu counter Read Not implemented
Control Settings
1 = Parallel; 2 = i/o; 3 = Remote; 4 = Constant flow; 5 = Constant pressure; 6 =
Linear pressure; 7 = Quadratic pressure; 8 = Quadratic pressure with maximum
av:3 0 0 Control Mode Read
flow; 9 = Quadratic pressure with minimum flow; 1 0 = Quadratic pressure with
minimum and maximum flow
av:3 0 1 hoa State Read/Write 0 = Off; 1 = Hand mode; 2 = Auto
av:3 02 Active Parameters Read/Write 1 = standard; 2 = mode 1 (heating mode); 3 = mode 2 (cooling mode)
av:3 03 Minimum Speed Limit Read in rpm
av:3 04 Maximum Speed Limit Read in rpm
av:3 0 5 Hand Mode Speed Read/Write in rpm
av:3 0 6 bms Set Speed Read/Write in rpm
Alarms and Warnings
av:40 0 Alarms Read Refer to alarms table for bit positions
av:40 1 Warnings Read Refer to warnings table for bit positions
av:402 Acknowledge Warnings Read/Write 3 2-bit field corresponding to the warning field
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

23

object id object name read/ write comments


Parameters
av:50 0 Standard mode – zero flow head Read Value for standard active mode. Unit as configured in pump control module
av:50 1 Standard mode – design head Read Value for standard active mode. Unit as configured in pump control module
av:502 Standard mode – design flow Read Value for standard active mode. Unit as configured in pump control module
av:503 Standard mode – minimum flow Read Value for standard active mode. Unit as configured in pump control module
av:504 Mode 1 – zero flow head Read Value for active mode 1 . Unit as configured in pump control module
av:50 5 Mode 1 – design head Read Value for active mode 1 . Unit as configured in pump control module
av:50 6 Mode 1 – design flow Read Value for active mode 1 . Unit as configured in pump control module
av:507 Mode 1 – minimum flow Read Value for active mode 1 . Unit as configured in pump control module
av:50 8 Mode 2 – zero flow head Read Value for active mode 2. Unit as configured in pump control module
av:50 9 Mode 2 – design head Read Value for active mode 2. Unit as configured in pump control module
av:5 1 0 Mode 2 – design flow Read Value for active mode 2. Unit as configured in pump control module
av:5 11 Mode 2 – minimum flow Read Value for active mode 2. Unit as configured in pump control module
i/o
ai:0 Analog in 1 Read As configured in pump control module
ai: 1 Analog in 2 Read As configured in pump control module
ao:0 Analog out 1 Read As configured in pump control module
bi:0 Digital in:1 Read As configured in pump control module
bi: 1 Digital in:2 Read As configured in pump control module
bo:0 Digital out:1 Read As configured in pump control module
bo: 1 Digital out:2 Read As configured in pump control module
bv:0 Relay 1 Read As configured in pump control module
bv: 1 Relay 2 Read As configured in pump control module
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

24

4 .0 operation Should the pump be noisy or vibrate on start-up a common


reason is overstated system head. Check this by calculating
4 .1 start-up checklist the pump operating head by deducting the suction pressure
Particular care must be taken to check the following gauge value from the discharge gauge reading. Convert the
before the pump is put into operation: result into the units of the pump head as stated on the pump
nameplate and compare the values. The system designer or
a Pump primed? operator should be made aware of this soon as some adjust-
b Rotation ok? ment may be required to the drive settings to make the pump
c Lubrication ok? suitable for the system as installed.
d Pipe work properly supported? Check rotation arrow prior to operating the unit. The
e Voltage supply ok? rotation of all Armstrong 430 0 & 438 0 Vertical
f Overload protection ok? In-Line units is clockwise when viewed from behind
g Is the system clean? the motor (nde).
h Is the area around the pump clean?

important:
Warranty
Do not run the pump for any length of time under
Does not cover any damages to the equipment resulting from
very low flow conditions or with the discharge valve
failure to observe the above precautions. Refer to Armstrong
closed. To do so could cause the water in the casing
General Terms and Warranty sheet. Contact your local Arm-
to reach super heated steam conditions and will cause
strong representative for full information.
premature failure and could cause serious and dramatic
damage to the pump and surrounding area.
4 . 2 starting pump
Ensure that the pump turns freely by hand, or with 4.2.1 auto flow balancing
some gentle mechanical help such as a strap or
Auto-Flow Balancing automatically determines the control
Allen key in coupling bolt.
curve between the design flow at the on-site system head,
Ensure that all protective guarding is securely fixed in position. and the minimum (zero-flow) head that will typically be
The pump must be fully primed on start up. Fill the pump lowered (reset).
casing with liquid and rotate the shaft by hand to remove any Often the actual system head is less than expected, and the
air trapped in the impeller. On split-coupled Design Envelope pump will operate further to the right of the curve at a higher
units any air trapped in the casing as the system is filled must flow rate than it was designed for due to less system resis-
be removed by the manual air vent in the seal flush line. En- tance. The Auto Flow Balancing function performs a scan of
sure entrained air is removed from Design Envelope pumps, the sensorless map against the actual system to establish the
prior to starting, through the air vent on the seal flush line. actual head for the design flow. The minimum (zero-flow)
Open vent until clear of air. head will be reset according to the actual head at the design
Design Envelope close-coupled units are fitted with seal flow – the factory default is 40% of the design head, but can
flush/vent lines piped to the pump suction area. When be lowered further for more energy savings if all zones are still
these units operate, residual air is drawn out of the pump satisfied.
towards the suction piping. energize the motor momentarily
and check that the rotation corresponds with the directional
arrow on the pump casing (clockwise when viewed from non-
drive end of motor).
Start the pump with the discharge valve closed and the suc-
tion valve open, then gradually open the discharge valve when
the motor is at operating speed. The discharge valve may be
cracked or open slightly at start up to help eliminate trapped air.
When stopping the pump: Close the discharge valve and
de-energize the motor.
Do not run the pump against a closed discharge valve at
full speed for an extended period of time (a few minutes For buildings that are commissioned in multiple stages, or
maximum.) where the design flow changes each time, the Auto Flow
Balancing function can be run at the beginning of each stage.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

25

From the touch screen, go to Pump Configuration -> Auto 4 .3 touch screen
Flow Balancing, then follow the on-screen instructions. The
4 .3 .1 login
Auto Flow Balancing scan takes approximately 3 minutes to
complete. Default Password 1234

1234

4 .3 . 2 logout

4 .3 .3 about

The physical design, software, &


user interface are protected by patents
& trademarks
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

26

4 .3 . 4 gener al set tings

save

save
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

27

4 .3 .5 manual /auto mode


i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

28

4 .3 .6 pump control

Activate Energy Performance Bundle

b a
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

29

Single

c d
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

30

Pressure Sensor Control

Pump is now setup for Pres-


sure Sensor Control.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

31

Pump is now setup for


2 Sensor Control

Pump is now setup for


Bypass Valve Control

4 .3 .7 alarms & warnings

5. VFD Parameter 16. Invalid VFD Parameter

One or more of the parame-


ters to control the vfd are not
correct. Check the settings on
the control card. If the alarm The control card has specified
persists after cycling power an invalid VFD parameter.
to the pump, contact an
Armstrong Technical Service
representative.
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4.3.8 trend-graph
There are 3 parameters that can be trended on the touch
screen interface:
• Power
• Flow
• Head
Which allows users to see a quick history of key performance data.

To see a more comprehensive view of the trends, the pump data


can be exported in CSV format for review and analysis on a sepa-
rate computing device.

4.3.9 brightness adjustment


To adjust the brightness of the touch screen interface, go to
Settings -> Brightness.
10 = highest brightness, 1 = lowest brightness

save
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

33

4.3.10 touch screen calibration


If you are having issues with the touch screen, including:
• Being unable to access items to the edge of the screen
• Some buttons from the display are unresponsive
The touch screen may require re-calibration. To calibrate the
touch screen, go to Settings -> Screen -> Calibration
Follow the following 3-step calibration sequence (touching
the squares) to reset the display coordinates.

Screen Calibration Screen Calibration Screen Calibration Screen Calibration

Screen has been


successfully calibrated

touch square touch square touch square

If you are unable to access the Calibration function from the


touch screen itself, connect the pump to the webserver and
go to Settings -> General -> Recalibrate LCD Screen. This will
trigger the calibration sequence on the touch screen of the
pump. Follow the above 3-step calibration sequence to reset
the display coordinates.
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4.3.11 data logging


Data logs can be used for energy performance analyses or to
troubleshoot system issues. The data logs can be used with
a building automation system (bas) or for each standalone
pump. Each pump controller logs the following data param-
eters over pre-defined time intervals (default is 5 minutes).
• Speed (rpm)
• Power (kW)
• Current (A)
• Flow (gpm)
• Head (ft)
• Analog Input 1
• Analog Input 2
• Analog Output
• Digital Input
• Digital Output
• Alarms
• Warnings
• kW-hours

The depc stores up to 3 months of data, at 5 min. intervals.


More data storage is available on the cloud server if the pump
is connected to the internet and has an active Pump Manager
subscription.

Connect the depc to the Webserver, in the Data -> Trends ->
Export Log File section.
Select the start date, the end date, and then click Export His-
tory to download the data log file in CSV format.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

35

4 . 4 web interface To access the control modes:

4 . 4 .1 connecting via ethernet Press settings  Pump

bms

Connect your device to the router via wifi or by Ethernet cable.


4 . 4 .3 switching frequency
The ivs drive controls have an adjustable carrier frequency,
or frequency at which the IGBTs are switched. The switching
frequency affects the performance of the drive and motor and
may produce an audible noise in some instances.
There are 2 pre-set modes available for the Switching
Frequency.

4 . 4 . 2 connecting via wifi

High Efficiency Mode - 5kHz, (default)


This frequency setting minimizes the losses in the drive and
motor for optimum performance. However, at this lower set-
ting, the motor may produce an audible high-pitched noise. If
noise is produced and unacceptable, then the drive can be set
At the web browser address bar, type the Pump’s ip (from
to Low Noise Mode.
Pump’s About screen).
Low Noise Mode – 12kHz
Default user level 1 Password: Armstrong1
This frequency setting increases electrical losses, but are less
Default user level 2 Password: Armstrong12
audible. Set the controls to the Low Noise Mode if the High
Efficiency Mode results in unacceptable audible noise.
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4 .5 design envelope flow readout 5 . 2 constant pressure


toler ance Design Envelope pumps can be configured to maintain a
Tolerance on flow and head readings between test stand in- constant pump head in a system as the demand varies. This
strumentation and Design Envelope controller readout will be effectively simulates the mounting of a differential pressure
within 5% of bep flow & head values for all Design Envelope sensor at, or near, the pump.
sensorless pump selections. head
1200

The same bep flow & head tolerance values will be carried 1000

to the Design Envelope selection point for that model 800


Constant Pressure Control Curve
(Guarantee point, to ansi 40.6 Hydraulic Institute Standard- 600
target curve
See fig . 4 .5 .1), as follows: 400

200
fig . 4 .5 .1 0
0 20 40 60 80 100 120 140 160 180 flow
Quadratic pressure control curve
80
Nominal BEP

5 .3 linear pressure
30% BEP flow 110% BEP flow
pump speed Guarantee &
70 verification point
Verification point

Head curve
Linear Pressure Control is where the controller is set to
Minimum speed Quadratic pressure
60 control curve Load limiting curve control the speed according to a control ‘curve’ between
50 max and min flow. This type of control will change the pump
Head (ft)

Region of
5% flow & head
accuracy
speed to ensure the pump operates on the projected linear
40
control curve, where the pump head varies directly with
30 the flow. This type of control is well known globally and is
54% Nominal
pump speed effective as far as the straight linear line will allow. For more
20
40% Nominal
pump speed
Sensorless Limit
realistic hvac control with superior energy savings, consider
10 the following control recommendation 5 . 4 Quadratic Curve
End of Envelope
Control.
0
0 100 200 300 400 500 600 700 800 900 head
1200
Flow (USgpm)
1000

The tolerance is applicable when the flow is between 30% 800


Linear Pressure Control Curve

and 110% of bep flow at Nominal Pump Speed; and the oper-
600

ating point is at 5 4% of Nominal Pump Speed, or greater; and 400


cur
ve
get
ta r
the motor power is 2hp, or greater. 200

0
180 flow
Flow readouts outside the above limits will be less accurate. 0 20 40 60 80 100 120 140 160

Nominal Pump Speed is displayed as the top speed on any 5 . 4 quadr atic curve control
Design Envelope pump curve. Quadratic Pressure Control is where the controller is set to
control the speed according to a control curve between max
and min flow. It is widely recognized that fitting a differential
5 .0 control modes pressure sensor at the most remote load, across the supply
piping and return piping encompassing the valve and coil set,
5 .1 constant flow is the benchmark scheme for energy efficiency.
Design Envelope pumps can be configured to maintain a Design Envelope pumps can replicate this control without
constant pump flow in a system as the system head varies. the need for the remote sensor. As the flow required by the
This effectively simulates speed control by a flow meter in system is reduced, the pump automatically reduces the head
the piping. developed according to the pre-set control curve.
head head
1200 1200

1000 1000
target curve
800 Quadratic Control Curve
800
Constant Flow Control Curve
600 600

curve
400 400 ta r g e t
200 200
0 0
0 20 40 60 80 100 120 140 160 180 flow 0 20 40 60 80 100 120 140 160 180 flow
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

37

5 .5 quadr atic curve control with 5 .7 quadratic curve control with mini-
minimum flow protection mum & maximum flow protection
This configuration is designed for hvac hydronic systems This control mode combines the control logic of 5 .5 & 5 .6
where flow sensitive equipment required a minimum flow for which takes the values of the quadratic control curve and
equipment stability; such as a chiller that cannot tolerate flow protection for both the maximum & minimum flow limits.
below a certain volume. This control will take advantage of Pump controls can only control the flow to the motor limit
the 5 . 4 Quadratic Curve Control mode, where the pump will or maximum / minimum speed limits of the unit, thus a
increase speed to maintain a minimum flow setting as the dry-contact relay is supplies which will close when either the
system load is shutting down. minimum or maximum flow is reached, which can be used for
Pump controls can only control the flow to the maximum an alarm or other device.
speed or motor limit; head
1200
5 .5 .1 A dry-contact relay is supplies which will close when
1000
minimum flow is reached, which can be used for an alarm target curve
800 Minimum & Maximum
or other device. Flow Settings
600
5 .5 . 2 When ordered, a minimum flow breach can be controlled
400
by opening a customer supplied 2-way (normally closed)
200
system bypass valve. The valve will be opened and closed 0
180 flow
as system flow, which is also monitored by the controls, 0 20 40 60 80 100 120 140 160

registers below or above the pre-set (adjustable) mini-


mum flow value, using the built-in outputs and relays in
5 .8 par allel sensorless pump control
the Design Envelope pumping unit on-board controls.
head
(pspc)
1200
This configuration maps the quadratic control curve into the
1000
target curve
pump controls and ensures the system flow requirements are
800
Minimum Flow Setting met, while staging the pumps on and off to maintain opti-
600
mum pump energy usage. This is accomplished by operating
400
the pumping units at the best pumping efficiency level for the
200
required flow.
0
0 20 40 60 80 100 120 140 160 180 flow
This control is available for 2, 3, or 4 Design Envelope pump
units operating in parallel. Tango and dualArm units have
5 .6 quadr atic curve control with Parallel Sensorless Pump Control (pspc) pre-programmed in
the controls at Armstrong factories. For all other models (ex-
maximum flow protection
cept twin pumps), pspc can be enabled aftermarket; please
This configuration is ideal for hvac hydronic systems where
contact your local Armstrong factory for details.
pumps are generally oversized and a flow limit is required
for system equipment stability and resulting energy savings. 1p eff 2p eff 3p eff 4p eff

This control will take advantage of the 5 . 4 Quadratic Curve


efficiency

Control mode, where the pump will decrease speed to main-


head

pspc control curve

tain a maximum flow setting. This will prevent over-pumping


ps
and save energy costs. Over-pumping is common in hvac 4-p
um

systems as pumps are typically oversized for the application. 3 -p u


mps

Pump controls can only control the flow to a minimum speed;


ps
2- pu m
1-pu mp

thus a dry-contact relay is supplies which will close when


maximum flow is reached, which can be used for an alarm or flow

other device.
5.8.1 embedded parallel sensorless pump con-
head
1200 trol for multiple pumps
1000
If the Parallel Sensorless Pump Control option was purchased
Maximum Flow Setting
800
for control of 2, 3 or 4 single pumps (VILs and End Suctions)
the function can be enabled at any time. Note that pumps
600

400 target curve must be of the same model for parallel operation.
200

0 Start by installing a wiring bridge between the pumps (sup-


180 flow
0 20 40 60 80 100 120 140 160
plied by others). The wiring between the control cards is a
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
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38

canbus (3-wire) cable with terminal blocks at each end (3 From the Webserver, choose Settings -> Pump, set control
position strain 3.81 mm). mode to Parallel with the following parameter values:
For connection of 3 or 4 pumps, the canbus connectors
should be daisy-chained together.
Wiring bridge supplied by others.

For 2 pump parallel operation:


Ensure that both terminating resistor switches are set to
Enabled (towards the en label for the canbus port).
lh lh
g g

A id: 1 to 8, the lower number is the lead pump


A = + Positive A = + Positive
B = - Negative
G = Ground
B = - Negative
G = Ground
e.g. enter 1 for lead pump, 2 for lag pump
B Dead Band: set to 0. 25
C Total Design Flow: enter the parallel flow rate
D Sensorless Map Adjust Factor: set to 0.1
e Minimum On Time (seconds): set to 15
Click update to save all changes. Connect the Webserver to
pump controller 1 pump controller 2 the second pump and then repeat above steps A to e.

For 3 or 4 pump parallel operation: 5 .9 2*100% capacity split units


Ensure that only the first and last terminating resistor When duty / standby is specified, enter the total system flow
switches are set to Enabled (towards the en label for the into ACE Online or ADEPT, then select 2*10 0% unit split for
canbus port). a superior customer value. The 10 0% flow redundancy is still
lh lh lh in place plus the onboard pspc will engage the second unit in
g g g
parallel operation should it predict lower operating costs.

If second side power is locked out, the operating pump will


operate alone on the control curve to 10 0% design flow.

A = + Positive
B = - Negative
G = Ground
A = + Positive
B = - Negative
G = Ground
A = + Positive
B = - Negative
G = Ground
5 .10 duty-standby mode
Duty-Standby mode allows only 1 pump head to operate at
a time while the second pump head is idle. To activate this
mode, use the Webserver and go to Settings -> Pump, and
then go the Control Mode section, under the Parallel tab, and
pump controller 1 pump controller 2 pump controller 3 input the Sensorless Map Adjust Factor to 10 0. Click update
lh
g
lh lh lh
g
to complete the change. Connect the Webserver to the sec-
g g
ond pump and repeat.

A = + Positive A = + Positive A = + Positive A = + Positive


B = - Negative B = - Negative B = - Negative B = - Negative
G = Ground G = Ground G = Ground G = Ground

pump controller 1 pump controller 2 pump controller 3 pump controller 4


Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

39

6.0 maintenance
6.1 gener al care
Vertical In-Line pumps are built to operate without periodic
maintenance, other than motor lubrication on larger units. A
systematic inspection made at regular intervals, will ensure
years of trouble-free operation, giving special attention to the
following:
• Keep unit clean
• Provide the motor with correctly sized overload protection.
Keep moisture, refuse, dust or other loose particles away
from the pump and ventilating openings of the motor.
• Avoid operating the unit in overheated surroundings
(Above 10 0°f/40°c).

Note that activating Duty-Standby mode effectively disables


the energy efficient staging of Parallel Sensorless operation. warning
To re-enable Parallel Sensorless control, set the Sensorless Whenever any service work is to be performed on a
Map Adjust Factor to 0.1. pumping unit, disconnect the power source to
the driver, lock it off and tag with the reason. Any
5 .11 alternation possibility of the unit starting while being serviced must be
eliminated. If mechanical seal environmental accessories are
Design Envelope Tango, dualARM, and Twin units are pre-
installed, ensure water is flowing through the sight flow
set to alternate lead-pump operation of each pump head to
indicator and that filter cartridges are replaced as recom-
achieve equal run hours. The default alternation interval is
mended. (See Armstrong files 43 . 85 and 43 . 86 for seal
10,0 8 0 minutes (1 week). This can also be set or adjusted for
environmental instructions).
multiple single pumps operating in sequence.
To change this setting, use the Webserver and go to Settings
-> Pump, and then go the Control Mode section, under the
Parallel tab, and input the Alternation Interval (in minutes) to 6. 2 lubrication
the new value. Press update to complete the change. Con- Pump
nect the Webserver to the second pump and repeat. Lubrication is not required. There are no bearings in the
pump that need external lubrication service.
Large Design Envelope 430 0 units are installed with a shaft
bushing located beneath the impeller that is lubricated from
the pump discharge.
Motor
Follow the lubrication procedures recommended by the
motor manufacturer. Many small and medium sized motors
are permanently lubricated and need no added lubrication.
Generally, if there are grease fittings evident the motor needs
periodic lubrication. None if not.
Check the lubrication instructions supplied with the motor for
the particular frame size indicated on the motor nameplate.

Warranty
Does not cover any damages to the equipment resulting from
failure to observe the above precautions. Refer to Armstrong
General Terms and Warranty sheet. Contact your local
Armstrong representative for full information.
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warning caution
Whenever any service work is to be performed on a Do not use oil, Vaseline or other petroleum or silicon
pumping unit, disconnect the power source to based products for seal elastomer lubrication.
the driver, lock it off and tag with the reason. Any Otherwise elastomer swelling may occur, causing
possibility of the unit starting while being serviced must be seal failure. Recommended: International Products Corp p-80
eliminated. If mechanical seal environmental accessories are Rubber Lubricant Emulsion in usa & uk www.ipcol.com
installed, ensure water is flowing through the sight flow
indicator and that filter cartridges are replaced as recom-
Seal Removal
mended. (See Armstrong files 43 . 85 and 43 . 86 for seal
environmental instructions). An important feature of the Series 4300 and 4302 pump is
that the design permits removal of the mechanical seal with-
warning out disturbing the pump, motor or electrical wiring.
Hydronic system components may be pressurized
a Disconnect the power supply at the main switch and close
which, if suddenly released, can cause serious injury
the isolating valves on the suction and discharge. Empty
or death. When performing any kind of service to
casing by removing drain plug(s) located at the bottom.
the pump, the pressure must be released in the
system and the unit should be properly drained b Loosen off the seal collar set screws (1) Remove the
before starting any service work. coupling screws (2) and separate the coupling halves
(3). Remove the motor shaft key (4) and the pump shaft
key (6). Do not remove motor collar (5) for seal replace-
ment. Use Allan wrench and insert coupling screw into
6.3 mechanical seal positioning hole (21) to prevent shaft rotation and remove
6.3 .1 mechanical seal replacement the capscrew, lockwasher and collar (17, 16, & 18) from the
instructions for 4300 split coupled pump shaft.
vertical in-line pump c Remove the mechanical seal rotating assembly (8)
19 through the gap between the pump and motor shafts.
d Disconnect the seal flush piping (10a). Mark seal plate
7 5 (10) position. Remove the seal plate bolts (9) and seal
3 1
4
plate (10). Remove the stationary seat (11) and seat
2 gaskets (13 & 14).
17
3
5 6
18 Seal Replacement
16
Handle mechanical seal carefully to protect seal faces from
21 6 damage. Do not contaminate seal faces with finger prints.
1 8 e Replace the stationary seat (11) and gaskets (13 &
2 4 14), aligning the seat flush hole with the seal plate
9 12 flush line connection. Ensure the large diameter gas-
10A ket (14) is on the bottom. Replace seal plate (10) and
15 tighten the seal plate bolts (9) evenly and diagonally,
to the following torque (ft. lbs) values: 1.125" seal – 20;
10 13 1.625"/2.125"/2.625" (7.5" diameter plate) – 50; 2.625 (9"
diameter) – 90; 3.5" – 90.
11 14
f When installing the mechanical seal (8), ensure parts are
20 perfectly clean.
g Apply a small amount of temporary rubber lubricant
emulsion to the o-ring (15). Carefully slide the mechanical
seal rotating assembly (8) down the shaft onto the sta-
tionary seat (11). Do not tighten the set screws (1) on the
side of the mechanical seal yet. Do not remove holding
clips (12).
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

41

If motor is replaced: Loosen set screws (7) on motor shaft 6.3 . 2 mechanical seal replacement instruc-
collar (5) and remove from old motor shaft. To position the tions for 4380 close coupled vertical
collar (5) correctly on the new motor shaft, temporarily fit in-line pump
motor shaft collar (5) into groove of the keyed coupling half.
Slide collar, with coupling half onto new motor shaft until
end of shaft lines up with line scored into coupling. Tighten
the visible set screws (7) in the collar (5) enough to hold
the collar in place on the shaft and remove the coupling 39 10
half. Tighten all collar set screws (7) evenly and diagonally.
Order replacement motors with locked lower bearing.
43
40
h Use Allan wrench and insert the coupling screw into 44
positioning hole (21) to prevent pump shaft rotation and
replace collar, lockwasher, and capscrew (18, 16, & 17). 60 104

Capscrew (17) must be firmly tightened on the pump 103

shaft with a wrench. 62


i Fit the motor shaft key (4) and the pump shaft key (6)
then install the keyed coupling half (3) first. 70 100

note:
For easier coupling installation, motor and pump shaft 101

keys (4 & 6) should be 180 degrees from the working area.


71 105 83 80
86
To automatically locate the impeller in the pump, insert
the coupling screw Allan wrench into positioning hole (21) For other Armstrong instructions pertaining to 436 0d &
and lift pump shaft until the pump shaft collar is posi- 438 0 pumps please refer to:
tioned in the coupling groove, then rotate shaft to locate Installation & Operating – File: 43 .64,
the pump shaft key (6) into blind keyway in coupling. Shaft Sleeve Replacement – File: 6 04 2. 25 ,
Should the pump rotating assembly prove too heavy to
Mechanical Seals Kits – File: 6 040.6 0
lift easily: a piece of 2" × 4" wood may be firmly posi-
tioned to allow a pry-bar to be placed securely under the The Series 436 0d and 438 0 pumps are motor mounted
pump shaft collar; the rotating assembly may be levered or close coupled type Vertical In Line pumps, on which are
and raised-up in that manner. mounted vertical shaft-down ball bearing motors. Each pump
j Place the second coupling half into position and tighten and motor unit is pipe mounted and as such relies on the
the coupling screws (2) following the tightening pattern piping only for support. The piping support is designed for
shown on the illustration(1 2 3 4 5 6). the weight of the piping, liquid, pump and motor and other
note: pipe fittings. The pumping unit should not be independently
Snug fit the coupling screws and confirm even gap spac- secured to the building structure. If the pump is mounted
ing between coupling halves, then firmly tighten cou- separately to any structure, the pump must be isolated from
pling screws following the tightening pattern illustrated. the piping with flexible piping connections. For units with
Then push (or slide) mechanical seal (8) firmly onto the larger motors it is advisable to install a permanent device for
stationary seat (11) and tighten the set screws (1) to the lifting the rotating assembly out of the pipe mounted casing
following torque (ft. lbs) values: Seal sizes 1.125" to 2.625" to service the unit.
– 5; 3.5" – 11. Remove the holding clips (12) for operation.
The mechanical seal is now preset at the correct working
Breakdown Procedures:
length.
k Replace the seal flush piping (10a) and drain plug(s). Se- caution
ries 4302: Equalize pump pressure within dualArm pump Exercise extreme care when handling power wir-
by temporarily opening valve on connecting tubing. ing. Ensure that the fuses are removed or breaker
Open all isolating valves prior to operating pump(s). disconnected in the power line to the motor. Power
Reconnect power supply. disconnect should be within sight of the pump
being serviced and tagged with the reason for
disconnection.

1 electrical wiring
If the pump and/or motor assembly is to be serviced on a
bench, the motor wiring must be disconnected.
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

42

2 isolation valves 9 remove seal seat from adapter


If the system is not drained: Ensure that the suction and dis- The mechanical seal seat [6 0], typically O-ring or L-cup
charge piping isolation valves are closed. Remove drain plug mounted Silicon Carbide material, is pried loose from the
[105] from the bottom of the casing and drain the pump. recess in the adapter. If the seat cannot be removed in this
manner, remove the motor capscrews [4 4] and separate the
3 prepare assembly for removal
adapter [40] from the motor [10]. A screwdriver may then be
Secure the motor [10], by lifting straps, to an overhead chain- used to push the seat out of the adapter from the rear.
fall or similar lifting device. The device must be designed to
lift the weight of the unit safely. Raise the lifter to bring the 10 remove old casing gasket
lifting straps taut. Disconnect the flush/vent tubing assembly The former casing gasket [101] should be scraped from
and place carefully to one side. Remove the casing capscrews the casing and adapter, leaving clean surfaces for the new
and washers [103 & 104]. Pry bars may then be inserted gasket. (A standard putty knife and wire brush are useful for
between the casing [10 0] and adapter [40]. Care should this purpose)
be taken not to apply pressure to the outside diameter of
the adapter, to prevent possible breakage, outside pressure Assembly Procedures:
should be on the casing only.
11 replace mechanical seal
4 remove rotating assembly
Clean the shaft sleeve [70] surface, ensuring all the former
The rotating assembly (Motor, adapter and impeller [10, 40 seal elastomer pieces have been removed. Inspect for dam-
& 8 0]) may now be lifted out of the casing. age. Replace if necessary. (See separate instructions for
removal of the shaft sleeve [File No. 6 04 2. 25]). Inspect the
5 rotating assembly notes
water slinger [39] and replace if damaged.
The impeller [8 0] is fastened directly to the motor shaft and
Install a new seal seat [6 0] in the adapter cavity, being sure
must be removed in order to replace the mechanical seal as-
the lapped (polished) side of the insert is facing up. Ensure
sembly [6 0/62]. This may be accomplished on a safe surface
that the cavity has been thoroughly cleaned. Lubricate the
near the installation or, more conveniently, on a work bench.
seat O-ring or L-cup with a small amount silicon or glycerine
6 impeller capscrew lubricant and press down, straight and even, into the cavity.
The impeller [80] should be prevented from rotating while Do not press the seat in with bare fingers, use a clean cloth or
the impeller capscrew [86] is loosened. A heavy screwdriver the cardboard disc typically supplied with the seal. Con-
may be inserted between the impeller blades to enable tamination of the polished and lapped seat face could cause
the impeller capscrew [86] to be backed off with a socket leakage. If the adapter was removed from the motor, replace
wrench. Remove the impeller capscrew and washer [86 & 83]. now, taking care that the seal seat is carefully guided over the
motor shaft.
7 pump impeller
Lubricate the inside of the seal rotating assembly [62] with
Using wheel pullers, with the jaws behind the rear shroud a small amount of silicon or glycerine lubricant and slide
of the impeller [8 0] (Behind a vane at each side) pull the onto the shaft sleeve [70] with a twisting motion, carbon
impeller free of the pump shaft. Impellers that are difficult to face first, until the carbon face is pressed firmly against the
remove may be loosened by heating the impeller hub with a seal seat [6 0]. Pressing on the seal rotating assembly metal
torch during the pulling process. Remove the impeller from parts, with a screw driver, all the way around the seal, will
the motor shaft. Note the impeller key and shaft sleeve ensure that the faces are mated properly. Remove the spring
spacer [7 1]. Remove both for storage. retainer from the seal spring and place the seal spring over
the seal rotating assembly. Series 436 0d and 438 0 units
8 remove mechanical seal from motor shaft
with frame 56c motors will have a shaft extension in place
The mechanical seal spring usually comes free with the impel- of an extended jm/jp shaft. This should be treated in exactly
ler. The mechanical seal rotating element [62] must be pried the same manner as described above for seal replacement.
loose with pry bars or screwdrivers, placed under each side of
the seal drive band. Leverage is applied against the adapter. 12 replace pump impeller
Once loosened, the seal may be pulled free of the shaft. Install the shaft sleeve spacer [71] and impeller key on the
Do not damage the carbon face when removing the rotating shaft and place the seal spring retainer onto the impeller hub
assembly. It may be needed for analysis if seal failure investi- register. Slide the impeller in place on the motor shaft.
gation is required. Take care and ensure that the seal spring is kept in place on
the seal rotating assembly and fits well into the retainer on
the impeller hub.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

43

13 tighten impeller capscrew 18 motor wiring


It is good practice to replace self locking screws, once re- The motor conduit and its wiring are now replaced. If the mo-
moved. Install the impeller capscrew and washer [83 & 86]. tor is new, double check that the voltage and rpm are identi-
Hold the impeller the same way as when the capscrew was cal to the original motor.
successfully loosened (Bar or screw driver placed carefully Be sure to check rotation of the motor after rewiring if the
between the impeller blades) and tighten the capscrew with a motor is three phase and correct if necessary, by switching
socket wrench. any two lead wires.
14 install new casing gasket Ensure that the pump is filled with water before operating to
check rotation.
Insert new casing gasket [101] into the gasket cavity in
the casing. 19 conduit box cover

15 lower rotating assembly into place The conduit box cover is replaced after checking the motor
rotation. The pump may now be placed in operation.
The rotating assembly (Motor, adapter and impeller combi-
nation) may now be lowered into place in the casing. The close-coupled or motor mounted type Vertical In-Line
pumps use vertical shaft-down ball bearing motors (inte-
16 casing capscrews grated motors and drives). Each pump and motor unit is pipe
The casing capscrews [104] are now installed and evenly mounted and as such relies on the piping only for support.
tightened with a wrench. Tighten the capscrews a little at a The piping support is designed for the weight of the piping,
time, diagonally across the casing, to assure even gasket liquid, pump and motor and other pipe fittings. The pump-
pressure. Replace the flush/vent tubing assembly ing unit should not be independently secured to the building
structure. If the pump is mounted separately to any structure,
17 isolation valves
the pump must be isolated from the piping with flexible pip-
Replace the casing drain plug and open the suction and dis- ing connections. For units with larger motors it is advisable
charge isolation valves. to install a permanent device for lifting the rotating assembly
out of the pipe mounted casing to service the unit.
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

44

7.0 warnings and alarms


7.1 alarm summary for interfaces
alarm
name alarm description
number
1 vsd over The temperature of a vsd or motor component is exceeding the thermal alarm limit. Turn off
temperature the power to the pump and verify that the motor, fan and vsd cooling is functioning correctly.
Verify that the pump is not overloaded. Wait until hot components have cooled before returning
to service and if the alarm persists after powering up contact an Armstrong Technical Service
representative.
2 vsd over The vsd has detected current exceeding the safe limit. Turn the pump off. (If there is a discharge
current from the output phases to earth it can be verified by checking for any faults with a megohmmeter
between ground and the motor leads). If a current limit has been exceeded in the vsd check that
the motor can be turned. If the pump is being overloaded reduce the pump speed using hand
mode control. If the alarm persists after powering up contact an Armstrong Technical Service
representative.
3 External vsd The voltage into the vsd is out of range. Verify that the correct voltage required to operate the vsd
voltage is present by measuring each of the 3 phases. If the alarm persists after cycling power to the pump,
contact an Armstrong Technical Service representative.
4 Internal vsd An internal voltage generated by vsd is out of range. If the alarm persists after cycling power to
voltage the pump, contact an Armstrong Technical Service representative.
5 Internal vsd An internal error in the vsd has occurred. If the alarm persists after cycling power to the pump,
contact an Armstrong Technical Service representative.
6 vsd parameter One or more of the parameters to control the vsd are not correct. Check the settings on the
control card. If the alarm persists after cycling power to the pump, contact an Armstrong Technical
Service representative.
7 vsd startup An error occurred during the startup of the motor. Turn off the power to the pump and verify
that the motor can be turned by using hand mode control. If the alarm persists after powering up
contact an Armstrong Technical Service representative.
8 Other vsd There has been an unknown alarm condition generated by the vsd. If the alarm persists after
cycling power to the pump, contact an Armstrong Technical Service representative.
9 vsd There is a communication issue between the control card and vsd. Turn off the power to the pump
communication and check the connections between the control card and the vsd.
10 vsd speed The speed set by the vsd is not within tolerance. If the alarm persists after cycling power to the
pump, contact an Armstrong Technical Service representative.
11 vsd The control card was not able to receive the initial parameters correctly. Please try to restart the
initialization pump. If the alarm persists after restart, contact an Armstrong Technical Service representative.
failure
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

45

7. 2 warning summary for interfaces


warning
name warning description
number
1 vsd over The temperature of a vsd or motor component is near the thermal warning limit. Check that the
temperature motor, fan and vsd cooling is functioning correctly. Verify that the pump is not overloaded. If the
warning persists, contact an Armstrong Technical Service representative.
2 vsd over current The vsd has detected current exceeding the warning limit. Turn the pump off. (If there is a
discharge from the output phases to earth it can be verified by checking for any faults with a
megohmmeter between ground and the motor leads.) If a current limit has been exceeded in
the vsd check that the motor can be turned. If the pump is being overloaded reduce the pump
speed using hand mode control. If the warning persists after powering up contact an Armstrong
Technical Service representative.
3 External vsd voltage The voltage into the vsd is out of range. Verify that the correct voltage required to operate the
vsd is present by measuring each of the 3 phases. If the warning persists, contact an Armstrong
Technical Service representative.
4 Internal vsd voltage An internal voltage generated by vsd is out of range. If the warning persists, contact an Armstrong
Technical Service representative.
5 Internal vsd An internal warning in the vsd has occurred. If the warning persists, contact an Armstrong
Technical Service representative.
6 Reserved
7 vsd startup A warning occurred during the startup of the motor. Turn off the power to the pump and verify
that the motor can be turned using hand mode control. If the warning persists after powering up
contact an Armstrong Technical Service representative.
8 Other vsd There has been an unknown warning condition generated by the vsd. If the alarm persists, contact
an Armstrong Technical Service representative.
9 vsd communication There is a communication issue between the control card and vsd.
10 vsd speed The speed set by the vsd is not within tolerance. If the alarm persists, contact an Armstrong
Technical Service representative.
11 vsd wiring There is an issue in wiring to the vsd. Check the wiring to the motor from the vsd. If any I/O are
used on the vsd, verify that there is continuity and no shorts for the connections.
12 System over The temperature measured by the control card is approaching the recommended operating
temperature conditions.
13 System under The temperature measured by the control card is approaching the recommended operating
temperature conditions.
14 Battery under The battery voltage is low. Replace the battery with cr 203 2 type cell.
voltage
15 bms communication bms communication has been lost.
loss
16 vsd communication The communication with the vsd and the control card has stopped.
loss
17 Invalid vsd The control card has specified an invalid vsd parameter.
parameter
18 vsd initialization The initialization of the vsd through Modbus has failed. Cycle power to the pump to re-initialize.
failure
19 vsd speed set failure The speed could not be set by the controller. Check the connections between the vsd and
control card.
20 vsd start set failure The controller could not start the motor. Check the connections between the vsd and control card.
21 Sensorless error The sensorless map that was entered has an error please refer to the I & O Manual for
further details.
22 Hand mode timeout The pump has been in hand mode too long. Consider setting to automatic mode to save energy.
i n sta l l at i on & Design Envelope 4300 & 4380 Vertical
o p era t i ng in str uction s In-line pumping unit with ivs drive

46

8.0 fuse and wire recommendation


table 1: ul fuses, 20 0 -240v
ul compliance fuses
frequency ferr az ferr az
bussmann bussmann bussmann siba lit tel fuse
converter shawmut shawmut
kW t ype rk1 t ype j t ype t t ype rk1 t ype rk1 t ype cc t ype rk1
k 25-k37 k tn-r0 5 jk s- 0 5 jjn- 0 5 50179 0 6 - 0 0 5 kln-r0 0 5 atm-r0 5 a 2k- 0 5r
k55-1k 1 k tn-r10 jk s-10 jjn-10 50179 0 6 - 010 kln-r10 atm-r10 a 2k-10r
1k5 k tn-r15 jk s-15 jjn-15 50179 0 6 - 015 kln-r15 atm-r15 a 2k-15r
2k 2 k tn-r 20 jk s-20 jjn-20 5012 40 6 - 020 kln-r 20 atm-r 20 a 2k-20r
3k0 k tn-r 25 jk s-25 jjn-25 5012 40 6 - 025 kln-r 25 atm-r 25 a 2k-25r
3k 7 k tn-r3 0 jk s-3 0 jjn-3 0 5012 40 6 - 03 0 kln-r3 0 atm-r3 0 a 2k-3 0r
5k5 k tn-r50 jk s- 50 jjn- 50 5012 40 6 - 0 50 kln-r50 - a 2k- 50r
7k5 k tn-r50 jk s- 6 0 jjn- 6 0 5012 40 6 - 0 50 kln-r6 0 - a 2k- 50r
11k k tn-r6 0 jk s- 6 0 jjn- 6 0 50140 0 6 - 0 63 kln-r6 0 a 2k- 6 0r a 2k- 6 0r
15k k tn-r8 0 jk s- 8 0 jjn- 8 0 50140 0 6 - 0 8 0 kln-r8 0 a 2k- 8 0r a 2k- 8 0r
18k5 k tn-r125 jk s-150 jjn-125 20282 20 -125 kln-r125 a 2k-125r a 2k-125r
2 2k k tn-r125 jk s-150 jjn-125 20282 20 -125 kln-r125 a 2k-125r a 2k-125r
3 0k f w x-150 - - 20282 20 -150 l 25 s-150 a 25 x-150 a 25 x-150
37k f w x-20 0 - - 20282 20 -20 0 l 25 s-20 0 a 25 x-20 0 a 25 x-20 0
45k f w x-250 - - 20282 20 -250 l 25 s-250 a 25 x-250 a 25 x-250

table 2: ul fuses, 380 -480v, 525- 60 0v


ul compliance fuses
frequency ferr az ferr az
bussmann bussmann bussmann siba lit tel fuse
converter shawmut shawmut
kW t ype rk1 t ype j t ype t t ype rk1 t ype rk1 t ype cc t ype rk1
k37-1k1 k ts-r6 jk s- 6 jjs- 6 50179 0 6 - 0 0 6 kls-r6 atm-r6 a6k- 6r
1k5-2k 2 k ts-r10 jk s-10 jjs-10 50179 0 6 - 010 kls-r10 atm-r10 a6k-10r
3k0 k ts-r15 jk s-15 jjs-15 50179 0 6 - 016 kls-r16 atm-r16 a6k-16r
4k0 k ts-r 20 jk s-20 jjs-20 50179 0 6 - 020 kls-r 20 atm-r 20 a6k-20r
5k5 k ts-r 25 jk s-25 jjs-25 50179 0 6 - 025 kls-r 25 atm-r 25 a6k-25r
7k5 k ts-r30 jk s-30 jjs-30 5012 40 6 - 032 kls-r30 atm-r30 a6k-30r
11k k ts-r 40 jk s-40 jjs-40 50140 0 6 - 040 kls-r 40 - a6k-40r
15k k ts-r 40 jk s-40 jjs-40 50140 0 6 - 040 kls-r 40 - a6k-40r
18k k ts-r50 jk s- 50 jjs- 50 50140 0 6 - 050 kls-r50 - a6k- 50r
2 2k k ts-r6 0 jk s- 6 0 jjs- 6 0 50140 0 6 - 0 63 kls-r6 0 - a6k- 6 0r
30k k ts-r8 0 jk s-8 0 jjs-8 0 20282 20 -10 0 kls-r8 0 - a6k-8 0r
37k k ts-r10 0 jk s-10 0 jjs-10 0 20282 20 -125 kls-r10 0 a6k-10 0r
45k k ts-r125 jk s-150 jjs-150 20282 20 -125 kls-r125 a6k-125r
55k k ts-r150 jk s-150 jjs-150 20282 20 -16 0 kls-r150 a6k-150r
75k f wh-2 20 - - 20282 20 -20 0 l50s-2 25 a50 -p2 25
9 0k f wh-250 - - 20282 20 -250 l50s-250 a50 -p250

k ts-fuses from Bussmann may substitute k tn for 2 40v frequency converters.


f wh-fuses from Bussmann may substitute f wx for 2 40v frequency converters.
kl sr-fuses from Littel Fuse may substitute klnr fuses for 2 40v frequency converters.
l5os-fuses from Littel Fuse may substitute l5os fuses for 2 40v frequency converters.
a6kr-fuses from Ferraz Shawmut may substitute a 2kr for 2 40v frequency converters.
a5ox-fuses from Ferraz Shawmut may substitute a 25 x for 2 40v frequency converters.
Design Envelope 4300 & 4380 Vertical i nsta l l a ti o n &
In-line pumping unit with ivs drive o perati ng i nstr ucti o ns

47

9.0 pump manager cloud


smart Connect router to cloud
Pump Manager is a cloud based analytics service providing device via cellular network
real time alerts and insights on the flow and the system’s ef- Connect cloud via
Smart device or VPN
ficiency. Pump Manager provides unique and critical insights
to drive savings in energy, maintenance, emergency repairs router
bas
and downtime costs. or

Features Connect pump to


network wirelessly
via Wifi
Secure IoT Connectivity

Plug 'n play setup, no l an connection required. Pump con- pumps


nected to the ibm Watson analytics platform cloud via a 4g
lte router with built-in cellular modem. Authentication key
and 1-way push notifications only with no inbound communi- Building Management System Integration
cation to pumps make for safe connection Integrate the pump data to your building automation system
Real Time Alerts via api so you can view all your assets in one place

Know of problems before they occur. Pump Manager will Benefits


alert you when something is wrong
Lower Operating Costs
Performance Reports
• Optimal operation for maximum energy efficiency
You can now view operation trends and make data informed
• Lower OpEx costs
decisions
Increase Availability & Reliability
Predictive Maintenance
• Reduce unexpected failures
The pump will advise which parts it needs! And tell you
• Early problem detection
where to buy them as well
• Faster return to service

Improve Comfort and Productivity


• Keep flows in the desired range, reducing temperature
swings

Improve Building Resilience and Future Decisions

• Make informed capital investment decisions

Start Now in Two Easy Steps


http://armstrongfluidtechnology.com/en/registration
or
info@armstrongfluidtechnology.com
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toronto, ontario
canada
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+1 416 755 2291

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+1 716 693 8813

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halesowen, west midlands
united kingdom
b62 8dj
+44 (0) 8444 145 145

manchester
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manchester
united kingdom
m11 2et
+44 (0) 8444 145 145

bangalore
#59, first floor, 3rd main
margosa road, malleswaram
bangalore, india
560 003
+91 (0) 80 4906 3555

shanghai
unit 903, 888 north sichuan rd.
hongkou district, shanghai
china
200085
+86 (0) 21 5237 0909

são paulo
rua josé semião rodrigues agostinho,
1370 galpão 6
embu das artes
sao paulo, brazil
+55 11 4785 1330

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