Professional Documents
Culture Documents
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
0.4
10
8
Overall Vibration Velocity (mm/s) RMS
0.3
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
1.1.8 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
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
Drain connection
fig . 1.1 Hanger supported pipe mounted
fig . 1. 4 With additional pipe supports
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
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
Drain connection
GAP
Stanchion plates
Isolation Pads
Stanchion plates
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)
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
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
95
Illustration : Terminals for mains and earthing.
95
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
13
14
3-Phase Power
input (1-ph
power: No 92 (l2)
connection)
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 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
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:
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.
A = + Positive
B = - Negative
G = Ground
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
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 ).
19
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
23
24
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
26
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
28
4 .3 .6 pump control
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
31
32
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.
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
34
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
bms
36
The same bep flow & head tolerance values will be carried 1000
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
and 110% of bep flow at Nominal Pump Speed; and the oper-
600
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
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
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.
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.
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).
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.
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
40
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
note:
For easier coupling installation, motor and pump shaft 101
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
43
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
45
46
47
buffalo
93 east avenue
north tonawanda, new york
u.s.a.
14120 -6594
+1 716 693 8813
birmingham
heywood wharf, mucklow hill
halesowen, west midlands
united kingdom
b62 8dj
+44 (0) 8444 145 145
manchester
wolverton street
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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tm