Armstrong 4302 IVS Series User manual

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FILE NO: 94.82L
DATE: Aug. 24, 2009
SUPERSEDES: New
DATE: New
Series 4302 IVS Vertical In-Line Pumping Unit
with Integrated Controls
INSTALLATION AND OPERATING INSTRUCTIONS
Product shown with coupling guards removed

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CE CONFORMITIES
For declaration of conformities contact Armstrong.
1.0 UNCRATING
Armstrong dualARM Design Envelope 4302 IVS in-line
pumps are thoroughly inspected before shipment to
assure they meet with your order requirements. After
removing the pump from the crate, make sure the
equipment is in good order and that all components are
received as called for on the packing list. Any shortages
or damage should be reported immediately. Use extreme
care in handling the unit, placing slings carefully so that
stress will not be imposed on the integrated controls,
pump or motor. NEVER PLACE CABLE SLINGS
AROUND THE PUMP SHAFT OR INTEGRATED CON-
TROLS. The eye bolts or lifting lugs on the motor are
intended for lifting only the motor and not the complete
unit.
1.1 HANDLING 4302 IVS & 4382 IVS UNITS
Series 4302 IVS & 4382 IVS dualARM units are handled
in a similar manner to the normal dualARM units. Extra
care is required to ensure the integrated controls do not
get damaged during lifting and installation. Remove the
coupling guards and insert lifting straps through each
pump/motor pedestal on the inner side of each coupling.
As the lifting device is engaged (Using a spacer bar if
necessary) and the straps tighten ensure no part of the
strapping is touching any part of the control or motor fan
cover. Lift the pumping unit carefully from the pallet in
this manner and allow the unit to stand upright on a flat
surface and re-position the straps, if necessary, to ensure
safe and damage free transportation into the pipe installa-
tion.
2.0 INSTALLATION
2.1 MECHANICAL INSTALLATION
2.1.1 LOCATION
 Locate the unit as close as practical to the liquid
being pumped, with a short, direct suction pipe.
Ensure adequate space is left above and around the
unit for operation, maintenance, service and
inspection of parts.
 Electric motor driven pumps should not be located in
damp or dusty location without special protection.
2.1.2 STORAGE
 Pumps not immediately placed into service, or
removed from service and stored, must be properly
prepared to prevent rusting
 Rotate the shaft periodically to keep rotating element
free.
 For long term storage, the pump must be placed in a
vertical position in a dry environment.
 Internal rusting can be prevented by removing the
plugs at the top and bottom of the casing and drain
or air blow out all water to prevent rust build up or
the possibility of freezing. Be sure to reinstall the
plugs when the unit is made operational.
Rustproofing or packing the casing with moisture
absorbing material and covering the flanges is
acceptable. When returning to service be sure to
remove the drying agent from the pump.
2.1.3 INSTALLATION
 The most important consideration when installing a
Series 4302 IVS pumping unit is to make sure the
pump is free to ‘float’ with expansion and contraction
of the piping. Recommended arrangements are:
 Supported from the ceiling by pipe hangers (See Fig.
2.1 on page 8)
 Pipe supported at the ceiling, with the dualARM
free-standing and mounted with an Armstrong Suc-
tion Guide & Flo-Trex valve. (See Figs. 2.2 & 2.3 on
page 8)
 Piping supported at ceiling with additional floor
mounted supports under Armstrong Suction Guide
and Flo-Trex Valve (See Fig. 2.4 on page 8)
 Floor mounted saddle supports (See Fig. 2.5 on
page 8)
 Where required, additional floor support may be
obtained as shown in Fig. 2.5. Note that the pump
must not be rigidly attached either to the plate or to
the block. Leave a 1/8” (3mm) gap between pump
and base. The piping must be installed in such a
manner that the pump is not used as a pipe support.
 DO NOT rigidly connect the pump to a permanent
base (See Fig. 2.7 on page 8) Note: if the pump
must be connected to a permanent base, the pump
must be isolated from the piping by flexible
connectors and the base isolated from the building
structure on an inertia base.
 DO NOT install the unit with the shaft horizontal.
 DO NOT support the installed unit by the motor eye
bolts or by supports to any other part of the pump other
than stated above.
2.1.4 PUMP PIPING - GENERAL
 Never connect a pump to piping, always start piping from
pump.
 Use as few bends as possible and preferably long radius
elbows.
 Do not use flexible connectors on the suction or
discharge.
 Make sure piping exerts no strain on pump as this
would distort the casing and cause pump
misalignment.
4382 IVS 4302 IVS
All Series 4302-IVS pumps contain a tapped hole in
the motor bracket above the discharge flange for
draining the well. Pipe this drain hole to a floor drain to
avoid overflow of the cavity caused by collecting
chilled water condensate or from seal failure.
IMPORTANT

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 Suction and discharge pipes may be increased at
pump nozzle to suit pump capacity and particular
conditions of installation. Use eccentric reducers on
suction connection.
 Lay out the suction line with a continual rise towards
the pump without high points, thus eliminating
possibility of air pockets that may prevent the pump
from operating.
 A strainer of three or four times the area of the
suction pipe, installed in the suction line, will prevent
the entrance of foreign materials into the pump.
1/8” (3mm) diameter perforations in the strainer are
typical.
 Test suction line for air leaks before starting; this
becomes essential with long suction line or static lift.
 Install, at pump suction, a straight pipe of a length
equivalent to 4 or 6 times its diameter; this becomes
essential when handling liquids above 120°F (49°C).
Armstrong suction guides may be used in place of
the straight pipe run and in line strainer.
 Install isolation valve in both suction and discharge
lines on flooded suction application; this valve is
used mainly to isolate the pump for inspection or
repair.
 Install a non-slam check valve in discharge line
between pump and isolation valve to protect pump
from excessive back pressure and to prevent water
running back through the pump in case of driver
failure. Armstrong Flo-Trex valve may be used in
place of check valve and isolation valve on pump
discharge.
2.1.5 ALIGNMENT
 The pumping unit is accurately aligned at the factory
prior to being shipped.
 Alignment on the 4302 dualArm may be verified by
assuring an equal gap between coupling halves on
both sides of the coupling.
OPERATION
2.1.6 STARTING PUMP
The pump must be fully primed on start up. Fill the pump
casing with liquid and rotate the shaft by hand to remove
any air trapped in the impeller. Air trapped in the casing
must be removed by the manual air vent in the seal flush
line. ENSURE ENTRAINED AIR IS REMOVED FROM
SERIES 4302 IVS PUMPS, PRIOR TO STARTING,
THROUGH THE AIR VENT ON THE SEAL FLUSH LINE
– OPEN VENT UNTIL CLEAR OF AIR.
 “Bump” or energize the motor for a fraction of a
second and check that the rotation corresponds with
the directional arrow on the pump casing.
 To reverse rotation of a three phase motor,
interchange any two power leads.
 Start the pump with the discharge valve closed and
the suction 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.
2.1.7 GENERAL CARE
 Vertical In-Line pumps are built to operate without
periodic maintenance. 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 100ºF [40 ºC]).
 If mechanical seal environmental accessories are
installed, ensure water is flowing through the sight
flow indicator and that filter cartridges are replaced
as recommended. (See file 43.85 & 43.86 for seal
environmental instructions).
2.1.8 LUBRICATION
PUMP
 Lubrication is not required. There are no bearings in the
pump.
MOTOR
 Follow the lubrication procedures recommended by
the motor manufacturer. Many small and medium
sized motors are permanently lubricated.
 Check the lubrication instructions supplied with the
motor for the particular frame size indicated on the
motor nameplate.
Discharge valve only must be used to reduce the
pump flow, not the suction valve.
Care must be taken in the suction line layout and
installation, as it is usually the major source of
concern in centrifugal pump applications.
CAUTION
Do not run the pump for any length of time under very
low flow conditions or with the discharge valve closed.
To do so could cause the water in the casing to reach
super heated steam conditions and will cause
premature failure and could cause serious and
dramatic damage to the pump and surrounding area.
IMPORTANT
Centrifugal pump rotation is generally “clockwise”
when viewing from the motor end.
Check rotation arrow prior to operating the unit
CAUTION
Whenever any service work is to be performed on
pumping unit, disconnect power source to driver.
Any possibility of the unit starting while being worked
on, must be eliminated.
WARNING

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MECHANICAL SEAL
 Mechanical seals require no special attention. The
mechanical seal is flushed from discharge of the pump
casing. Seal environmental controls, installed in flush
lines, such as filters and separators, will prolong seal life
in hvac systems.
 Do not run the pump unless properly filled with
water as the mechanical seals need a film of liquid
between the faces for proper operation. (See file
43d.88 for mechanical seal replacement
instructions)
2.1.9 SYSTEM CLEANLINESS
 Before starting the pump the system must be thoroughly
cleaned, flushed and drained and replenished with clean
liquid.
 Welding slag and other foreign materials, “Stop
Leak” and cleaning compounds and improper or
excessive water treatment are all detrimental to the
pump internals and sealing arrangement.
 Proper operation cannot be guaranteed if the above
conditions are not adhered to.
ARMSTRONG dualARM HVAC PUMP FLAPPER
VALVE OPERATING INSTRUCTIONS
This dualARM HVAC pumping unit is fitted with internal
valves to allow isolation of one pump for service and to
automatically prevent recirculation of the flow when only
one pump is running.
PROCEDURE FOR PARALLEL OR STAND-BY
PUMPING
Discharge and suction valve stems should be locked
in the center position. This is indicated by both locking
handles in the vertical position and the center pin of
the locking arms (4) locked by the handles. This
procedure allows the discharge flapper valves to pivot
freely and locks the suction valve firmly in the center
position.
PROCEDURE FOR ISOLATION OF ONE SIDE
1. Stop the pump to be serviced.
2. Close and lock the suction and discharge valves: as
per instructions below.
3. Ensure seal flushline interconnection valve is closed
and drain the isolated casing.
4. Service isolated pump as required.
PROCEDURE FOR STARTING THE PUMP AFTER
SERVICING
1. Ensure serviced pump is fully re-assembled including
all seal flush lines and drain plugs.
2. Fill the dry casing with system fluid by opening the
seal flushline interconnecting valve and the air vent
fitting.
3. Allow the pressure to equalize in the two casings, if
necessary, by opening seal flush line interconnected
valve.
4. Unlock the discharge valve as per instructions below.
5. Unlock the suction valve as per instructions below.
6. Close the seal flushline interconnect valve and restart
pump.
VALVE OPERATION - Refer To Valve Illustration On
Page 6 (3”, 4” & 6” Valve) Or Page 7 (8” Valve)
DISCHARGE VALVE
This valve performs the dual function of automatically sealing
the discharge of the inactive pump when one pump is running
and can manually be closed and locked to isolate one pump
for service.
AUTOMATIC FLAPPER OPERATION
In the flapper mode the two halves of the discharge valve
are free to pivot independently under normal operating
conditions. The locking handle (3) should be secured with
the set screw (11) in the vertical position with the center
pin of the locking arm (4) trapped by the locking
handle (3).
MANUAL VALVE LOCKING
The locking feature of this valve is to ensure a positive
seal (leak proof) of the discharge port on the pump to be
serviced.
LOCKING:
1. Loosen discharge side set screw (11) to release the
locking handle (3).
2. Rotate the discharge side locking handle (3) so that
the handle points toward the pump to be serviced
and secure in the horizontal position, using set screw
(11). This releases the discharge locking arm (4).
NOTE
Particular care must be taken to check the
following before the pump is put into operation:
A. Pump primed?
B. Alignment correct?
C.Rotation OK?
D.Lubrication OK?
E. Pipe work properly
supported?
F. Voltage supply OK?
G. Overload protection OK?
H. Is the system clean?
I. Is the area around the pump clean
J. Pipe work properly supported?
Refer to Armstrong General Terms and Warranty
sheet. Contact your local Armstrong representative for
full information.
WARRANTY
KEEP HANDS AND TOOLS AWAY FROM LOCKED
SUCTION VALVE ARM, AS THE DIFFERENTIAL
PRESSURE MAY CAUSE THE ARM TO ROTATE
QUICKLY WITH FORCE WHEN UNLOCKED.
NOTE
ENSURE THE PUMP TO BE ISOLATED IS NOT
OPERATING BEFORE ATTEMPTING TO RELEASE
THE LOCKING MECHANISM. FAILURE TO DO SO
MAY RESULT IN INJURY TO THE OPERATOR
AND/OR DAMAGE TO THE PUMP.
NOTE

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3. Rotate discharge valve shaft (16) towards the pump
to be isolated. The orientation of the shaft is indicated
by the center pin on the locking arm (4).
4. Raise the locking handle (3) so that the cam on the
base of the handle forces the pin of the locking arm
(4) towards the pump to be isolated. The locking
handle (3) should be raised to between 45 degrees
and the vertical position.
5. Tighten set screw (11) to lock the locking handle (3)
in position.
THIS HANDLE SHOULD NOT BE ROTATED PAST
THE VERTICAL POSITION.
UNLOCKING:
1. Open the interconnecting valve on the seal flushline
to pressurize the serviced pump and vent air through
bleeder valve on series 4302. Close these valves
once the pressure is equalized and air removed.
2. Loosen set screw (11) and lower locking handle (3)
to the horizontal position, secure with set screw (11).
3. Rotate valve to center position so that the center pin
of the locking arm (4) locates in the recess on the
locking handle (3).
4. Loosen set screw (11) and raise locking arm (3) to
the vertical position, locking the center pin in the
locking arm recess, secure with set screw (11).
SUCTION VALVE
MANUAL OPERATION
The suction side valve is designed for use as a manually
operated isolation valve. This valve is not designed to
automatically pivot as the discharge flappers do.
LOCKING:
1. Loosen suction side set screw (11) to release the
locking handle(3).
2. Rotate the suction side locking handle (3) so that the
handle points towards the pump to be serviced and
secure in the horizontal position, using set screw
(11). This releases the suction locking arm (4).
3. Rotate the suction valve towards the pump to be
isolated. The orientation of the shaft is indicated by
the center pin on the locking arm (4).
4. Loosen set screw (11) and raise the locking handle
(3) so that the cam on the base on the handle forces
the pin of the locking arm (4) towards the pump to be
isolated. The locking handle (3) should be raised to
between 45 degrees and the vertical position.
THIS HANDLE SHOULD NOT BE ROTATED PAST
THE VERTICAL POSITION.
5. Tighten set screw (11) to secure the locking handle (3) in
position.
UNLOCKING:
1. Open the interconnecting valve on the seal flushline
to pressurize the serviced pump and vent air through
bleeder valve on series 4302. Close these valves
once the pressure is equalized and air removed.
2. Loosen set screw (11) and lower locking handle (3)
to the horizontal position, secure with set screw
(11).
3. Rotate valve to center position so that the center pin
of the locking arm (4) is located in the recess on the
locking handle (3).
4. Loosen set screw (11) and raise locking arm (3) to
the vertical position, locking the center pin in the
locking arm recess, secure with set screw
ENSURE THE ISOLATED PUMP IS NOT
OPERATING BEFORE ATTEMPTING TO RELEASE
THE LOCKING MECHANISM. FAILURE TO DO SO
MAY RESULT IN INJURY TO THE OPERATOR
AND/OR DAMAGE TO THE PUMP.
NOTE
Care should be taken when performing procedures 3) and
4) below. Read the following instructions carefully.
WARNING
THE LOCKING HANDLE (3) SHOULD ONLY BE
ROTATED TOWARDS THE PUMP STOPPED FOR
SERVICE. THE dualArm SUCTION VALVE IS
DESIGNED TO PREVENT THE LOCKING HANDLE
(1) FROM ROTATING TOWARDS THE RUNNING
PUMP, AS THE SUCTION OF THE RUNNING PUMP
COULD CAUSE THE VALVE TO SLAM SHUT WITH
SUFFICIENT FORCE TO INJURE THE OPERATOR
AND/OR CAUSE DAMAGE TO THE PUMP. DO NOT
ATTEMPT TO CIRCUMVENT THIS SAFETY
FEATURE.
NOTE
Care should be taken when performing procedures 3)
and 4) below. Read the following instructions
carefully.
WARNING
KEEP HANDS AND TOOLS AWAY FROM SUCTION
VALVE LOCKING ARM WHEN FREED BY LOCKING
HANDLE AS DIFFERENTIAL PRESSURE MAY
CAUSE ARM TO ROTATE QUICKLY WITH FORCE
WHEN UNLOCKED.
NOTE