Armstrong The Brain DRV80R 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 qualified installer.
For further information, please call our technical department at [phone].
The Brain®
DRV80
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 DRV80 Pack Contents................................ 5
DRV80 Dimensions................................................ 6
Specifications ........................................................ 8
Standards and Codes........................................ 8
Default Settings ................................................. 9
Installation............................................................ 10
General ............................................................. 10
Installation Requirements .............................. 11
Piping Diagrams .............................................. 12
Installation DRV80 ............................................... 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
DRV80 Display Alerts .......................................... 39
DRV80 Error Messages ....................................... 39
Connectivity......................................................... 40
System Performance........................................... 41
DRV80 Digital Recirculation
Mixing Valve
Preventative Maintenance and Fitting
Spare Parts........................................................... 42
DRV80 Disassembly ............................................ 43
Electronics Module.............................................. 44
PCB Connections ................................................ 47
DRV ....................................................................... 48
Troubleshooting................................................... 58
Contents........................................................... 58
DRV80 Display Errors...................................... 59
Common Faults ............................................... 62
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
The Brain® DRV80 is a registered trademark of Armstrong Hot Water Group, a division of Armstrong International.
DRV80 features RadaTechnology, Rada is a registered trademark of Kohler Mira Limited of Cheltenham, England.
The DRV80 is a digital recirculating valve for use as part of a warm water recirculation system within a commercial
installation.
A dedicated PC / Laptop with Microsoft Windows based control program can monitor and control temperature
limits, disinfection and temperature warning alerts.This product can be linked to external control and monitoring
devices such as a Building Management System. Data connections can be made via USB plug-in or Serial Port.
DRV80 Control Software and USB Cable Drivers are available to download and update at
www.armstronginternational.com/brain
Safety
Applicable codes must be followed and supersede any other
instructions. Generally applicable codes in the US include:
• IPC (International Plumbing Code)
Read this manual
Improper installation or operation may cause a flood resulting in
property damage, personal injury, or death. Armstrong strongly
recommends that a qualified installer be used.
Service must be performed by a qualified 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 five 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
The use of the word ‘failsafe’ to describe the function of any hot and cold water mixing valve is both incorrect and
misleading.This DRV (Digital Recirculation Valve) incorporates additional shut-off devices to improve the 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
with the information supplied with the disinfectant and with all relevant Guidelines / Approved Codes of 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 profits, business or anticipated savings, or loss or corruption of data, or any indirect or consequential
loss arising out of the customer's use of DRV80. The customer shall be solely responsible for the independent
backup of all data / information stored on DRV80. Notwithstanding the foregoing, none of the exclusions and
limitations stated above are intended to limit any rights the customer may have under local law or other 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 DRV80 Pack Contents
*2 x CR - P2 6V Batteries fitted as supplied.
USB Driver and The Brain®DRV80 Control 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
DRV80 Dimensions
8"
(202 mm)
5-11/16"
(144 mm)
6’ 9"
(3m approx)
power cable
length
10-9/16"
(268 mm)
4"
(102 mm)
3” NPT
Internal

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
10-5/8"
(270 mm)
2"
(51 mm)
minimum
recommended
clearance
6-3/4"
(172 mm)
1-3/16"
(30 mm)

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Technical Specifications
General
Protection NEMA 3S (IPx4)
Ambient Temperature minimum ambient temperature of 2 °C maximum 50 °C
Ambient Humidity 95% Non-condensing
Connections 3” NPT 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 DRV80 10.5 kg
Pressures
Maximum Inlet Supply Pressure Static Pressure 1034 kPa (10.3 bar)
Dynamic Pressure 862 kPa (8.6 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 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 625 l/min at 2.3 m/s
Minimum Recirculation Flow Rate 38 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
Specifications
Standards and Codes
The Brain® DRV80 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
Default Settings
DRV80 is preprogrammed to customer requirements prior to shipment
The settings are derived from the Installation Detail Form (IDF) filled out by the customer when placing an order.
The Installation Detail Form (IDF) is available to download at www.armstronginternational.com/brain
or consult factory
Armstrong Hot Water Group
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
Notes:
1. DRV80 is supplied fully performance and pressure tested.
2. The DRV80 must be installed in an area where it is accessible to do 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 DRV80 must be “tapped” directly from the cold inlet supply to the water heater.
6. The inlet supply pipework must be thoroughly flushed before fitting the DRV80.
200 mm
50 mm
100 mm 100 mm
150 mm
50 mm
The Brain®DRV80 MUST ONLY
be installed in this orientation.
These clearance dimensions are
recommended for maintenance
purposes.
Installation must be carried out in accordance with these instructions, and must be conducted by
designated, qualified 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 DRV80 must be installed per the piping diagrams (pages 12 - 15). All plumbing components are to be
supplied by the installer. Failure to include these components will compromise the DRV and system performance.
Caution! The DRV80 must be installed in a dry area where it will not be able to freeze
(minimum ambient temperature of 2 °C).
Warning! The DRV80 must be EARTHED.
The DRV80 is intended to be permanently connected to the fixed electrical wiring.
A means for electrical isolation of the DRV80 shall be provided, this device must
be suitably located, easily reached and identified as to its purpose.

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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 DRV80 for ease of maintenance.
It is recommended that outlet isolating valves (full flow type) are also installed.
The use of supply / return strainers will reduce debris entering the DRV80.The recommended
gauge for such strainers is 35 mesh (mesh aperture dimension 0.5mm).
Inlet pressure tappings which allow measurement of the inlet pressures to the DRV80 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 flushed before
connection to the DRV80.
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
DRV80 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
Mixed Flow
Piping Diagrams
Items are installer
supplied
Figure 12-1. Single Valve Installation
Note: For 0-90 GPM (0-340 l/min) Systems the DRV80 inlet connections are 2”
Note: For 0-150 GPM (0-567 l/min) Systems the DRV80 inlet connections are 3”

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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
DRV80 Assembly
Swing Check Valve*
- Legend -
Thermometer
Isolation Valve
*Orientated for piping
schematic detail only.
Must be installed in
horizontal plane.
Figure 13-1. Dual Valve 300 GPM (1135 l/min) Installation
Note: DRV80 inlet connections are 3”.
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

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Wafer Style Spring
Check Valve
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
DRV80R 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. Single Valve Installation
Note: For 0-90 GPM (0-340 l/min) Systems the DRV80R inlet connections are 2”
Note: For 0-150 GPM (0-567 l/min) Systems the DRV80R inlet connections are 3”
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
Wafer Style Spring
Check Valve
In-Line Check Valve
DRV80R 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. Dual Valve 300 GPM (1135 l/min) Installation
Note: DRV80R inlet connections are 3”.
Items are installer
supplied

16
Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Installation - DRV80
Before fitting to the pipework, it is
recommended that connectors are fitted 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 fitted for
options such as BrainScan® or an error relay.
If these are required but have not been prefitted,
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 fit the 4 pin plug at this
stage. To prevent a back EMF the system
must be flooded with water before the 4 pin
plug is fitted.
Connect the power cable to the primary power
supply via switched circuit breaker with a 3
Amp fuse.
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 mm contact separation gap in each pole.This
disconnection device should be located near to
the DRV80 and identified to its purpose.
Commission the DRV80 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
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.
Close all the mixed water outlets and turn on
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 flow isolation valve(s).
• Open the hot water supply isolation valve(s).
• Once flooded, 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 DRV80 to function.
1
2
3
Commissioning
Commissioning must be carried out in accordance with these instructions by designated, qualified and competent
personnel.
4
4mm HEX
5
6

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Armstrong International
Parc Industriel Des Hants-Sarts, 2ème Avenue No. 4, Haerstal, B-4040, Belgium
armstronginternational.com/brain
Temp. 48˚C
Setpoint 49˚C
DRV80
Temp. 48˚C
Setpoint 49˚C
Rada
Display as seen during normal operating mode
Current Outlet Temperature
Current Setpoint
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 specified on the
Installation Detail Form (IDF).
7

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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 DRV80 Control Software by double clicking the icon on the desktop or search for and run the
file Brain DRV Programming Software.exe
Operation
1
2
3
4
5
Electronics Module