Armstrong DRV40 User manual

1
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
The installation and service must be performed by a qualied installer.
For further information, please call our technical department at [phone].
The Brain®
DRV40
Digital Recirculation Valve
Keep this manual with installation
for future reference.

2
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Contents
Introduction ............................................................ 3
Safety ...................................................................... 3
General Advisory ................................................... 4
Data Storage ...................................................... 4
Patents ............................................................... 4
Single DRV40 Pack Contents ............................... 5
DRV40 Dimensions ................................................ 6
Specications ........................................................ 8
Standards and Codes ....................................... 8
Default Settings ................................................. 9
Installation ............................................................ 10
General ............................................................. 10
Installation Requirements .............................. 11
Piping Diagrams .............................................. 12
Installation DRV40 ............................................... 16
Commissioning .................................................... 18
Operation .............................................................. 20
Control Software .................................................. 21
Introduction ..................................................... 21
COM Port .......................................................... 22
DRV Information .............................................. 24
Temperatures ................................................... 25
Setpoints .......................................................... 26
Setpoints - Explained ...................................... 28
Alerts - Explained ............................................ 29
Preset Display Alerts ....................................... 31
Disinfection ...................................................... 32
Disinfection Step by Step - 1 ...................... 36
Disinfection Step by Step - 2 ...................... 37
Options ............................................................. 38
DRV40 Display Alerts .......................................... 39
DRV40 Error Messages ....................................... 39
Connectivity ......................................................... 40
System Performance ........................................... 41
DRV40 Digital Recirculation
Mixing Valve
Preventative Maintenance and Fitting
Spare Parts........................................................... 42
DRV40 Disassembly ............................................ 43
Electronics Module.............................................. 44
PCB Connections ................................................ 47
DRV ....................................................................... 48
Troubleshooting .................................................. 57
Contents ........................................................... 57
DRV40 Display Errors ..................................... 58
Common Faults ............................................... 61
Notes..................................................................... 69
Limited Warranty and Remedy ........................... 72

3
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Introduction
TheBrain®DRV40isaregisteredtrademarkofArmstrongHotWaterGroup,adivisionofArmstrongInternational.
DRV40featuresRadaTechnology,RadaisaregisteredtrademarkofKohlerMiraLimitedofCheltenham,England.
TheDRV40isadigitalrecirculatingvalveforuseaspartofawarmwaterrecirculationsystemwithinacommercial
installation.
A dedicated PC / Laptop with Microsoft Windows based control program can monitor and control temperature
limits,disinfection and temperaturewarning alerts.Thisproductcan belinked to externalcontrol andmonitoring
devicessuch asa Building ManagementSystem. Dataconnections canbe made via USB plug-inor SerialPort.
DRV40 Control Software and USB Drivers are available to download and update at
www.armstronginternational.com/brain
Safety
Applicable codes must be followed and supersede any other
instructions.
Read this manual
Improper installation or operation may cause a ood resulting in
property damage, personal injury, or death. Armstrong strongly
recommends that a qualied installer be used.
Service must be performed by a qualied person.
Improper installation, start-up, operation, maintenance, or service
may void the warranty.
Hot water or metal may cause scald burns. Skin exposure to 60°C
water or metal for only ve seconds may cause a second degree burn.
Icon Legend
If instructions are not followed:
- injury or death and property damage are imminent
- injury or death and property damage are possible
- potential property damage, expensive repairs, and / or voiding the warranty may result

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Data Storage
Theuse ofthe word ‘failsafe’to describethe functionof anyhot and cold water mixingvalve isboth incorrect and
misleading.ThisDRV(DigitalRecirculationValve)incorporatesadditional shut-offdevices to improvethe level of
safety however, in keeping with every other mechanism it cannot be considered as being functionally infallible.
Where chloramine / chlorine disinfection is practiced, DO NOT exceed a chloramine / chlorine concentration
of 50 mg/l (ppm) in water, per one hour dwell time. Such procedures must be conducted strictly in accordance
withthe informationsupplied with the disinfectant and with all relevant Guidelines/Approved Codesof Practice.
Water must have levels of chloramine / chlorine lower than or equal to 4mg/l (ppm) for continual usage.
General Advisory
Armstrong International shall not accept liability in contract, tort (including negligence or otherwise) for any
loss of prots, business or anticipated savings, or loss or corruption of data, or any indirect or consequential
loss arising out of the customer's use of DRV40. The customer shall be solely responsible for the independent
backup of all data / information stored on DRV40. Notwithstanding the foregoing, none of the exclusions and
limitationsstated aboveare intendedto limitany rightsthe customermay haveunder locallaw orother statutory
rights which may not be excluded.
Patents
GB - 2 421 297 2 437 891
US - 7669776 8043556
PCT - PCT/GB2006/000159
European - 06702758.1
India - 1231/MUMNP/2007
Australia - 2006207367
Canada - 2595064
China - ZL200680005853.8
Japan - 4933451

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Single DRV40 Pack Contents
*2 x CR - P2 6V Batteries tted as supplied.
USB Driver and The Brain® DRV Programming Software are available to download from website,
www.armstronginternational.com/brain
2 x Electronics Module
Screws
3 x Hexagonal Keys
(1 x 2.5mm)
(1 x 3mm)
(1 x 4mm)
1 x Electronics Module*
1 x DRV
Digital
Recirculation
Valve
1 x Circlip
1 x DB9 - PC USB RS485 Cable
(for connecting Laptop / PC to
Electronics Module).

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
DRV40 Dimensions
3m
power cable
length
172 mm
144 mm
55 mm AF Hex
1-1/2 BSP
Internal
268 mm

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
240 mm
50 mm
minimum
recommended
clearance
140 mm
67 mm

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Technical Specications
General
Protection NEMA 3S (IPx4)
Ambient Temperature minimum ambient temperature of 2 °C maximum 50 °C
Ambient Humidity 95% Non-condensing
Connections 1 1/2 BSP Internal (female)
Installation Environment Suitable for indoor use only
Materials Electronics Module: PC / ABS
DRV: Stainless Steel, engineering plastics and elastomers
Safety Thermal shutdown upon inlet supply failure and / or power failure
Weight DRV40 5.2 kg
Pressures
Maximum Inlet Supply Pressure 1379 kPa (13.8 bar)
Maximum Operating Pressure
Drop across DRV 140 kPa (1.4 bar)
Supply Pressure Differential Inlet supply pressures must be nominally equal
Temperatures
Maximum Inlet Hot Water Supply 85°C
Minimum Inlet Hot Water Supply 2°C above set point
Maximum Inlet Cold Water 25°C
Minimum Inlet Cold Water 2°C
Set Point Range 27°C to 70°C
Minimum Recirculation Loop
Temperature Loss 1°C
Recirculation Circuit
Minimum distance to First Outlet 7.6 m
Flow Rates
Maximum Suggested Flow Rate 155 l/min at 2.3 m/s
Minimum Recirculation Flow Rate 19 l/min
Minimum System Draw-off 0 l/min during recirculation
Electrical
Power Supply 230V AC ~ 50Hz
Supply Fuse / Circuit Breaker Switched type 3 Amp
Battery 2 x CR - P2 6V
Duty Cycle Continuously rated
Auxiliary Relay (see Alerts - Activate Relay on Alert)
Relay Type Single pole changeover relay contacts
Power Supply 230V AC / 24V DC
Supply Fuse 2 Amp
Specications
Standards and Codes
The Brain® DRV40 conforms to the CE marking requirements.
2004/108/EC EMC Directive
2006/95/EC Low Voltage Directive
2011/65/EU RoHS Directive
EN 61326-1
EN 61000-3-2
EN 61000-3-3
EN 61010-1
EN 50581

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
DRV40 is preprogrammed to customer requirements prior to shipment
Thesettingsare derived fromthe Installation Detail Form (IDF) lled out by the customer when placing an order.
Default Settings
The Installation Detail Form (IDF) is available to download at www.armstronginternational.com/brain
or consult factory
Armstrong HotWaterGroup
221 Armstrong Blvd
Three Rivers, MI 49093
Phone: [phone]
Fax:[phone]
Digital Recirculating Valve (DRV) and Digital Mixing Center (DMC)
Installation Details Form (IDF)
In order to enter P.O.'s and guarantee delivery dates, a technically accurate and complete IDF is required.
The review and acceptance of the information on the IDF by Armstrong:
1. Approves the order for processing which triggers an e-mail confirmation
2. Indicates that AHWG supports you by endorsing the application
3. Initiates the warranty
4. Delivers a complete, AHWG supported performance guarantee to the final user of the product
5. Drives the relevant point of specification/influence, point of installation and point of order financial allocation if appropriate
Section 1 - Ordering Processing/Tracking Detail:
Point of Order (Sold To):
(eg: ABC Mechanical)
City:
State:
Rep Firm:
Point of Installation:
(eg: Heinz Ketchup)
City:
State:
Rep Firm:
Point of Specification:
(eg: DEF Consulting Engineers)
Other Influence:
(eg:Source of Recommendation)
Section 2 – Product Technical Detail:
1.
DRV40 DRV50 DRV80
2.
Inlet Hot Water Temp:
°F
3.
Inlet Hot Water Pressure:
PSI
4.
Inlet Cold Water Temp:
°F
5.
Inlet Cold Water Pressure:
PSI
6.
Maximum Simultaneous Demand:
GPM
7.
Recirculation Pump Flow:
GPM
Section 3 – Digital Recirculation Valve (DRV) Option Detail:
1.
DRV Outlet Water Temperature (OWT):
°F
2.
BS No
Yes
Section 4 - Package Reference Information
Reference Drawing #
Armstrong Model #
List Any Non-Standard Variations:
BS
Protocol Options (Select One)
LonWorks
Modbus RTU
Modbus TCP
BACnet Metasys N2
BACnet MSTP
BACnet IP
Web Browser Interface
TCP/IP Configuration
DRV & DMC IDF Dec 2014

10
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
General
Installation must be carried out in accordance with these instructions, and must be conducted by
designated, qualied and competent personnel.
The installation must comply with all relevant national and local water plumbing regulations.
The installation must comply with all relevant national and local electrical wiring regulations.
The DRV40 must be installed per the piping diagrams (pages 12 - 15). All plumbing components are to be
suppliedbythe installer.Failureto include thesecomponentswill compromise theDRVandsystemperformance.
Installation
Caution! The DRV40 must be installed in a dry area where it will not be able to freeze
(minimum ambient temperature of 2 °C).
Warning! The DRV40 must be EARTHED.
The DRV40 is intended to be permanently connected to the xed electrical wiring.
Ameans forelectricalisolation ofthe DRV40shall beprovided, thisdevice must
be suitably located, easily reached and identied as to its purpose.
Notes:
1. DRV40 is supplied fully performance and pressure tested.
2. The DRV40 must be installed in an area where it is accessible for any maintenance tasks e.g. connecting
Laptop / PC, removal of the cover, replacing worn parts, etc.
3. Suitable connections for ease of maintenance should be used on the inlet and outlet ports. (Isolation valves
and unions.)
4. The hot and cold water inlet supply pressures must be nominally equal.
5. The cold inlet supply feed to the DRV40 must be “tapped” directly from the cold inlet supply to the water
heater.
6. The inlet supply pipework must be thoroughly ushed before tting the DRV40.
200 mm
50 mm
100 mm 100 mm 150 mm
50 mm
The Brain®DRV40 MUST ONLY
be installed in this orientation.
These clearance dimensions are
recommended for maintenance
purposes.

11
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Installation Requirements
Inlet isolating valves (full flow type) must be installed close to the DRV40 for ease of
maintenance. It is recommended that outlet isolating valves (full ow type) are also installed.
The use of supply / return strainers will reduce debris entering the DRV40. The recommended
mesh aperture dimension = 0.5 mm.
Inlet pressure tappings which allow measurement of the inlet pressures to the DRV40 under
operating conditions are particularly recommended for in-service testing.
Pipework must be rigidly supported to avoid any strain on the connections.
Make sure the pipe layout will avoid the build up of trapped air in the system. Air release valves
can be used where this is not possible.
Inlet and outlet threaded joint connections should be made with PTFE thread sealing tape or
liquid sealant. Do not use oil-based, non-setting joint compounds.
To eliminate pipe debris it is essential that supply pipes are thoroughly ushed before
connection to the DRV40.
1
2
3
4
5
6
7

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
H C
Isolation Valve
Sink
Shower
Thermometer
Strainer
Cold Water
Hot Water
Mixed Water
Check Valve
Recirculation Pump
System Layout
- Legend -
Stop Valve
DRV40 Assembly
Swing Check Valve*
- Legend -
Thermometer
Isolation Valve
*Orientated for piping
schematic detail only.
Must be installed in
horizontal plane.
Outlets
Return to
Hot Water
Supply Inlet
Cold Water
Supply
Mixed Return
From Hot Water
Supply
Outlets
DRV
Figure 12-1. DRV40 Single Valve Installation
Note: DRV40 inlet connections are 1.5”.
Mixed Flow
Piping Diagrams
Items are installer
supplied

13
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
CH CH
Isolation Valve
Sink
Shower
Thermometer
Strainer
Cold Water
Hot Water
Mixed Water
Check Valve
Recirculation Pump
System Layout
- Legend -
Stop Valve
DRV40 Assembly
Swing Check Valve*
- Legend -
Thermometer
Isolation Valve
*Orientated for piping
schematic detail only.
Must be installed in
horizontal plane.
Figure 13-1. DRV40 Dual Valve Installation
Note: DRV40 inlet connections are 1.5”.
Outlets
Outlets
Mixed Return
Cold Water
Supply
Return to
Hot Water
Supply Inlet
From Hot Water
Supply
Mixed Flow
DRV DRV
Items are installer
supplied

14
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
In-Line Check Valve
Isolation Valve
Sink
Shower
Thermometer
Strainer
Cold Water
Hot Water
Mixed Water
Check Valve
Recirculation Pump
System Layout
- Legend -
Stop Valve
DRV40R Assembly
- Legend -
Balancing Valve
Swing Check Valve*
Thermometer
Isolation Valve
*Orientated for piping
schematic detail only.
Must be installed in
horizontal plane.
H C
Figure 14-1. DRV40R Single Valve Installation
Note: DRV40 inlet connections are 1.5”.
DRV
Outlets
Outlets
Mixed Return
Cold Water
Supply
Return to
Hot Water
Supply Inlet
From Hot Water
Supply
Mixed Flow
Items are installer
supplied

15
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Isolation Valve
Sink
Shower
Thermometer
Strainer
Cold Water
Hot Water
Mixed Water
Check Valve
Recirculation Pump
System Layout
- Legend -
Stop Valve
Balancing Valve
In-Line Check Valve
DRV40R Assembly
- Legend -
Swing Check Valve*
Thermometer
Isolation Valve
*Orientated for piping
schematic detail only.
Must be installed in
horizontal plane.
Outlets
Outlets
Mixed Return
Cold Water
Supply
Return to
Hot Water
Supply Inlet
From Hot Water
Supply
Mixed Flow
DRV DRV
H C H C
Figure 15-1. DRV40R Dual Valve Installation
Note: DRV40R inlet connections are 1.5”.
Items are installer
supplied

16
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Installation - DRV40
Before fitting to the pipework, it is
recommended that unions are tted to the
inlets and outlet. This will enable the DRV
to be easily removed, if required.
Flush pipework thoroughly
(minimum of 5 minutes).
Fit the DRV to the pipework.
Attach the Electronics Module and secure
using the circlip supplied.
1
2
3
4
Hole markers inside the Electronics Module
case indicate where cables can be tted for
options such as BrainScan® or an error
relay. If these are required but have not been
pretted, contact Armstrong for further advice.

17
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Connect and secure the 8 pin plug to the back
of the Electronics Module.
Important! Do not t the 4 pin plug at this
stage. To prevent a back EMF the system
must be ooded with water before the 4 pin
plug is tted.
Connect the power cable to the primary power
supply.
A separate, permanently connected supply
must be taken from the ring main to the
appliance through a 3 Amp double pole
switched fuse spur providing a minimum of
3 mmcontact separationgap in each pole.This
disconnection device should be located near to
the DRV40 and identied to its purpose.
Commission the DRV40 and recirculation system using the following instructions...
6
7
5
Power Cable

18
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
4mm
HEX
Commissioning
Commissioning must be carried out in accordance with these instructions by designated, qualied and competent
personel.
Ensure that the system is powered and
the display on the Electronics Module is
illuminated.
Make sure the hot and cold inlet supplies
are at their designated pressures and
temperatures.
Closeall the mixed water outletsand turnon
the circulating pump.
Ensure the system is powered off and the 4 pin plug is unplugged on the electronics module.
Flood the system in the following sequence:
• Open the cold water supply isolation valve(s).
• Open the outlet ow isolation valve(s).
• Open the hot water supply isolation valve(s).
• Once ooded, connect and secure the 4 pin plug to the electronics module.
Close and secure the Electronics Module with the 2 x 4mm hexagon socket screws provided.
Note! The Electronics Module must be closed for the DRV40 to function.
1
2
3
4
5
6

19
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
The LCD display will indicate the outlet water temperature and the outlet water temperature setpoint.
The setpoint was preprogrammed at the factory according to the installation details specied on the
Installation Detail Form (IDF).
Temp. 48˚C
Setpoint 49˚C
Temp. 48˚C
Setpoint 49˚C
Rada
DRV40
Display as seen during normal operating mode
Current Outlet Temperature
Current Setpoint
7

20
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Temperature Adjust Using Laptop or PC
Operating System: Microsoft Windows XP, Vista or Windows 7, Windows 8 - 8.1 and Windows 10.
Minimum Screen Resolution: 1024 x 768 (Recommended 1280 x 1024 or higher.)
Download and install:
USB Driver - www.ftdichip.com/Drivers/VCP.htm
The Brain(R) DRV Programming Software - www.armstronginternational.com/brain
Connect the Laptop / PC to the Electronics Module with PC USB Cable supplied.
Connect the cable to the serial port on the Electronics Module and the Laptop / PC.
Run the DRV Programming Software by double clicking the icon on the desktop or search for and run
the le Brain DRV Programming Software.exe
Operation
1
2
3
4
5
Electronics Module