Armstrong 4302 IVS Series User manual

1
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

2
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

3
 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

5
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

6
VALVE ILLUSTRATION (3”, 4” and 6”)
SUCTION VALVE DISCHARGE VALVE
4
16
This pump suction is now closed. (Locked when
handle is elevated and secured).
This pump discharge is now closed. (Locked when
handle is elevated and secured).
Normal Operation
3
11
Normal Operation

7
VALVE ILLUSTRATION (8”)
SUCTION VALVE DISCHARGE VALVE
16
This pump suction is now closed. (Locked when
handle is elevated and secured).
This pump discharge is now closed. (Locked when
handle is elevated and secured).
Normal Operation Normal Operation
4
3
11

8
Fig. 2.4 With additional pipe supports
Fig. 2.1 Hanger supported pipe mounted
Fig. 2.5 Floor saddle support
Fig. 2.7 Not recommended
Fig. 2.6 Additional floor support
Fig. 2.8 Tapped collection well on Series 4302 IVS
Fig. 2.3 Discharge elbow for minimum footprint
Fig. 2.2 Pipe mounted supported at ceiling
Series 4302 IVS seal leaks
or condensate drain hole.
Plumb to drain for area
cleanliness

9
INTEGRATED CONTROLS
POWER RATINGS 0.55 to 7.5kW
3.1 ENCLOSURE RATING
The standard enclosure rating for IVS Sensor-
less pumps is IP55. If the pump is to be in-
stalled in a wet or dusty environment then a
higher enclosure rating may be required (IP56
or IP66 option).
3.2 AMBIENT TEMPERATURE
To avoid the inverter unit getting overheated,
the ambient temperature is not to exceed 40°
C and the 24 hour average temperature is not
to exceed 35°C. If the ambient temperature is
in the range of 40°C - 55°C, a reduction of the service life
of the inverter part is to be expected.
4.0 ELECTRICAL INSTALLATION
All electrical connections should be carried out
by a qualified and authorised electrician in ac-
cordance with local site regulations and the
latest issue of the IEE regulations.
SAFETY, RISK OF DEATH
Before removing the inverter cover, the system
must be disconnected from the mains supply.
After switching off wait for at least 5 minutes for
the capacitors to discharge before opening the
cover.
CAUTION
High voltage testing (Megging) of the motor /
inverter may cause damage to the electronic
components and therefore should not be car-
ried out.
4.1 EARTH LEAKAGE CURRENT
Earth leakage current is primarily caused by the
capacitance between motor phases and the
motor frame. The RFI filter contributes addi-
tional leakage current, as the filter circuit is con-
nected to earth through capacitors.
The size of the leakage current to the ground depends of
the following factors, in order of priority:
1. Switching frequency
2. Motor grounded on site or not
The leakage current is of importance to safety during han-
dling / operation of the IVS Sensorless pump if (by mis-
take) the on-board inverter has not been earthed.
NB!
Since the leakage current is >3.5mA (approx 4-
20mA), reinforced earthing must be established
which is required if EN 50178 is to be complied
with. Never use ELCB relays that are not suitable for DC
fault currents (type A).
If ELCB relays are used, they must be:
 Suitable for protecting equipment with a direct current
content (DC) in the fault current (3-phase bridge recti-
fier)
 Suitable for power-up with short charging current to earth
 Suitable for a high leakage current
4.2 START / STOP OF PUMP
The number of starts / stops via the mains voltage must
not exceed 1 time per 2 mins.
If a higher number of starts / stops is required then the
start / stop digital input must be used (mains voltage di-
rectly connected). This is the preferred method of starting
and stopping IVS Sensorless Pumps.
THE 3 PHASE MAINS MUST BE ISOLATED
BEFORE PERFORMING MAINTENANCE OF
THE PUMP.
4.3 ADDITIONAL MOTOR PROTECTION
With the exception of supply fuses / MCB’s to protect the
installation, no additional overload or over-temperature
protection is required. Motor / inverter protection includes:
 Mains phase loss
 Over voltage
 Under voltage
 Over current
 Short circuit
 Over temperature
4.4 SUPPLY VOLTAGE
The supply voltage details can be found on the motor
nameplate. Please ensure that the motor is suitable for
the electrical supply on which it is to be used. The mains
supply for IVS Sensorless pumps is as follows:
3 x 380/400/415/440/460/480V +/- 10%
Supply frequency - 50/60Hz
4.5 TOOLS FOR INSTALLATION
1 Cross point screwdriver, 1 Large screwdriver,
1 Small screwdriver
4.6 CABLE ENTRY SIZES
0.55kW - 4.0kW: 3 x M20 x 1.5
5.5kW - 7.5kW: 1 x M25 x 1.5, 2 x M20 x 1.5
One cable entry is factory fitted with a plug kit for external
keypad connection.
4.7 MAX. CABLE CROSS SECTION
Mains cable supply: 4.0mm
2
Control cable: 1.5mm
2
Serial communication cable: 1.5mm
2

10
Figure 2. Inverter Terminal Arrangement
4.8 MAINS SUPPLY CONNECTION
i. Remove the inverter box cover, which is held by four
screws (6 on 5.5 and 7.5kW units), to obtain access to
the terminals.
ii. Remove the detachable terminal plugs from the termi-
nal blocks X100 and X101 to obtain access to the
mains terminals.
iii. Lift only the corner of the black plastic cover by the
cable entries to expose the mains terminals L1, L2
and L3.
DO NOT lift or remove the entire plastic
cover. This is part of the inverters protective
arrangements.
Mains Terminals L1, L2 and L3
Make sure that your mains supply corre-
sponds to the voltage required by the IVS
Sensorless unit (see motor nameplate), TT
and TN mains.
iv. Remove the gland plug furthest from the drive end of
the motor (to the right in fig. 2) and feed the mains
cable through the hole.
v. Connect the three mains phases to terminals L1, L2
and L3 and the earth to the separate terminal pro-
vided.
DO NOT over-tighten the mains terminals
as this will damage the unit!
0.55 - 4.0kW torque - 0.5 to 0.6Nm
5.50 - 7.5kW torque - 1.2 to 1.5Nm
Earth terminal - 3.4Nm
vi. Remove the middle gland plug and feed the control
cable through the hole (see the section on control
connections for wiring details).
vii. The third entry is fitted with a plug kit to facilitate key-
pad connection. Do not remove the kit or wiring unless
as serial communications link (to BMS) is required.
You cannot change the rotational direction
of the pump by shifting around the input
mains phases. The direction of rotation is
factory set.
4.9 CONTROL CONNECTIONS
Terminal blocks X100, X101 and X102 are used for con-
trol connections. Individual terminal allocation is as fol-
lows:
X100 TERMINALS
The X100 terminals are used for data communications,
either as part of a serial communications network or for
connection to the cable gland mounted plug kit for key
pad connection (Default).
YW
GN
RD
BE
P N
5V 0V
This switch is only used for
serial communications to
BMS and should otherwise
be left in the off position.

11
X101 TERMINALS - CONTROL TERMINALS
The X101 terminals are used for analogue and digital
signals that will determine the operation of the pump (see
the section on Control Modes).
 Terminal 1 - 4-20mA input for a remote feedback de-
vice (when Sensorless control is not used).
 Terminal 2 - 0-10V input for a reference signal (when
Sensorless control is not used).
 Terminal 3 - Digital input for a low water device (pump
only runs if input is ‘logic 1’) - factory linked with zero
ohm resistor to terminal 6.
 Terminal 4 - Digital input for pump start (pump en-
abled when ‘logic 1’).
 Terminal 5 - Digital input for pump mode (if left at
‘logic 0’ then pump will be in sensorless mode).
 Terminal 6 - 24VDC supply for terminals 3 to 5 (max
150mA).
 Terminal 7 - 10VDC supply for terminal 2 when used
with a potentiometer (max 15mA).
 Terminal 8 - 0V for terminals 1 to 7 and 9.
 Terminal 9 - Digital output for ‘pump fault’ connection
to BMS (voltage level will be 24VDC when pump has
a fault).
NB: Terminal 9 is not a volt-free contact. Con-
nection of an external voltage will destroy the
unit.
X102 TERMINALS - PUMP RUNNING
The X102 terminals provide a relay changeover contact
for identification of pump running.
Terminals 1 - 2 will be made when the pump is running.
Voltage level at contact/load (AC) 250VAC, 5A
Voltage level at contact/load (DC) 30VDC, 5A; 40VDC,
2A; 100VDC, 0.5A
4.9.1 CONNECTION EXAMPLES
There are many ways that an IVS Sensorless pump can
be configured. The following is some examples of the
most common control configurations.
i. SENSORLESS PRESSURE CONTROL - CONNEC-
TION DETAILS
IVS Sensorless pumps are factory configured to be con-
nected as shown below. For a description of sensorless
pressure control please refer to the programming section.
ANALOGUE CURRENT INPUT
ANALOGUE VOLTAGE INPUT
LOW WATER DIGITAL INPUT
PUMP START DIGITAL INPUT
PUMP MODE DIGITAL INPUT
24VDC POWER SUPPLY
10VDC POWER SUPPLY
0V COMMON
PUMP FAULT DIG OUTPUT
Fault
Output
Running
Output

12
ii. FULL SPEED OVERIDE - CONNECTION DETAILS
It may be required to run the pump at full speed without
automatic speed control (e.g. during system commission-
ing). This can be achieved without programming changes
by making the control connections shown below.
iii. CONSTANT CURVE MODE - BMS SPEED CON-
TROL
Where the Building Management System is to be used for
speed control it is necessary to disable sensorless control
and provide the unit with a 0 - 10VDC speed reference
signal.
As shown above, in Constant Curve mode the pump will
speed up and slow down according to the voltage level of
the reference signal. On a unit configured for 50Hz pump
speed the reference signal is scaled (by default) so that
0V on X101 terminal 2 will equate to 0Hz and 10V will
equate to 50Hz.
iv. CONSTANT CURVE MODE - POTENTIOMETER
SPEED CONTROL
If a potentiometer is to be installed for manual control of
pump speed then the control connections will be as fol-
lows:
The recommended minimum speed for IVS
Sensorless pumps is 580rpm. Running for long
periods below this speed can damage the me-
chanical seal.
Running
Output
Fault
Output
Running
Output
Fault
Output
Running
Output
Fault
Output

13
5.0 PROGRAMMING, MONITORING AND DI-
AGNOSTICS
A key pad tool (LCP) is available for IVS Sensorless
Pumps as an option. The LCP gives the user full pro-
gramming and monitoring capabilities and it is recom-
mended that at least one LCP and cable kit are pur-
chased for each installation site.
The LCP is connected via a cable to the ‘plug kit’
mounted in one of the inverter cable entries as shown
above.
5.1 LCP FUNCTIONS AND OPERATION
The functions of the control panel can be
divided into three groups:
• Display
• Keys for changing program parameters
• Keys for local operation
All data is indicated by means of a 4-line alphanumeric
display, which in normal operation is able show 4
measurements and 3 operating conditions continuously.
During programming, all the information required for
quick, effective parameter Setup of the IVS Sensorless
Pump will be displayed. As a supplement to the
display, there are three LEDs for voltage, warning and
alarm. All program parameters of the IVS Sensorless
Pump can be changed immediately from the control
panel, unless this function has been blocked via
parameter 018.
5.1.1 DISPLAY
The LCD-display has rear lighting and a total of 4
alpha-numeric lines together with a box that shows the
direction of rotation (arrow) and the chosen Setup as well
as the Setup in which programming is taking place if that
is the case.
1st line shows up to 3 measurements continuously in
normal operating status or a text which explains the 2nd
line.
2nd line shows a measurement with related
unit continuously, regardless of status (except
in the case of alarm/warning).
3rd line is normally blank and is used in the menu mode
to show the selected parameter number or parameter
group number and name.
4th line is used in operating status for showing
a status text or in data change mode for showing
the value of the selected parameter.
An arrow indicates the direction of rotation
of the pump (factory set). Furthermore, the Setup
which has been selected as the Active Setup in
parameter 004 is shown. When programming
another Setup than the Active Setup, the number
of the Setup
which is being programmed will appear to the right. This
second Setup number will flash.
5.1.2 LED’S
At the bottom of the control panel is a red alarm LED and
a yellow warning LED, as well as a green voltage LED.
If certain threshold values are exceeded, the alarm and/or
warning lamp lights up together with a
status and alarm
text on the control panel. The voltage LED is activated
when the IVS Sensorless Pump receives voltage; at the
same time the rear lighting of the display will be on.

14
5.1.3 CONTROL KEYS
The control keys are divided into functions. This means
that the keys between display and indicator LEDs are
used for parameter Setup, including choice of display
indication during normal operation.
Keys for local control are found under the
indicator LEDs.
Control key functions
[DISPLAY / STATUS] is used for selecting the
mode of display or for changing back to Display
mode from either the Quick menu mode or the
Menu mode.
[QUICK MENU] is used for programming the
parameters that belong under the Quick menu
mode. It is possible to switch directly between
Quick menu mode and Menu mode.
[MENU] is used for programming all parameters.
It is possible to switch directly between Menu
mode and Quick menu mode.
[CHANGE DATA] is used for changing the
parameter selected either in the Menu mode or
the Quick menu mode.
[CANCEL] is used if a change of the selected
parameter is not to be carried out.
[OK] is used for confirming a change of the
parameter selected.
[+/-] is used for selecting parameter and for
changing the chosen parameter or for
changing the read out in line 2.
[<>] is used for selecting group and to
move the cursor when changing numerical
parameters.
[STOP / RESET] is used for stopping or for
resetting the pump after a drop-out (trip). Can be
selected via parameter 014 to be active or
inactive. If stop is activated, line 2 will flash, and
[START] must be activated.
NB!:
Pressing [STOP/RESET] will prevent the pump
from running also with disconnected LCP.
Restarting is only possible via the LCP [START]
key.
[JOG] overrides the output frequency to a preset
frequency while the key is kept down. Can
be selected via parameter 015 to be active or
inactive.
[FWD / REV] changes the direction of rotation of
the motor, which is indicated by means of the
arrow on the display although only in Local. This
key is inactive by default.
[START] is used for starting the pump after stop
via the [Stop] key. Is always active, but cannot
override a stop command given via the terminal
strip.
5.1.4 DISPLAY MODE
In normal operation, up to 4 different operating
variables can be indicated continuously: 1,1 and 1,2 and
1,3 and 2, and in line 4 the present operating status or
alarms and warnings that have arisen.
There are three options in connection with the
choice of read-out state in the Display mode - I, II and III.
The choice of read-out state determines the number of
operating variables read out.

15
The table below gives the units linked to the variables in the
first and second line of the display (see parameter 009).
Operating variable: Unit:
Reference [%]
Reference [unit]*
Feedback [unit]*
Frequency [Hz]
Frequency x scaling [-]
Motor current [A]
Torque [%]
Power [kW]
Power [HP]
Motor voltage [V]
DC-link voltage [V]
FC thermal [%]
Hours run [Hours]
Input status, dig. Input [Binary code]
External reference [%]
Status word [Hex]
Heat sink temp. [ºC]
Alarm word [Hex]
Control word [Hex]
Warning word 1 [Hex]
Warning word 2 [Hex]
Analog input 1 [mA]
Analog input 2 [V]
Sensorless power [W]
Sensorless flow [l/s]
Sensorless head [kpa]
*) Select in parameter 416. The unit is shown in readout
state 1 line 1 otherwise ’U’ is shown.
Operating variables 1,1 and 1,2 and 1,3 in the first line,
and operating variable 2 in the second line are selected
via parameter 009, 010, 011 and 012.
Read-out state I:
This read-out state is standard after starting up or after
initialisation.
Line 2 gives the data value of an operating variable with
related unit, and line 1 provides a text which explains line
2, cf. table. In the example, Frequency has been selected
as variable via parameter 009. During normal operation
another variable can immediately be read out by using the
[+/-] keys.
Read-out state II:
Switching between read-out states I and II is effected by
pressing the [DISPLAY / STATUS] key.
In this state, data values for four operating values are
shown at the same time, giving the related unit, cf. table.
In the example, Reference, Torque, Current and
Frequency are selected as variables in the first and
second line.
Read-out state III:
This read-out state can be held as long as the
[DISPLAY/STATUS] key is pressed. When the key is
released, the system switches back to Read-out state II,
unless the key is pressed for less than approx. 1 sec.
This is where parameter names and units for operating
variables in the first line are given—operating variable 2
remains unchanged
.
5.1.5 QUICK MENU
Quick menu gives access to a limited number of parame-
ters but does not include parameters that may need to be
changed when utilising sensorless control. It is therefore
recommended that parameter changes are made in the
standard menu.
5.1.6 MENU MODE
The Menu mode makes it possible to select and change
all parameters at the user’s option. However, some
parameters will be "missing", depending on the choice of
configuration (parameter 100), e.g. open loop hides all the
PID parameters. In addition to having a name, each
parameter is linked up with a number which is the same
regardless of the programming mode. In the Menu mode,
the parameters are divided into groups, with the first digit
of the parameter number (from the left) indicating the
group number of the parameter in question. Regardless of
the mode of programming, a change of a parameter will
take effect and be visible both in the Menu mode and in
the Quick menu mode.
The Menu mode is started by pressing the [MENU] key,
which produces the following read-out on the display:
Line 3 on the display shows the parameter
group number and name.

16
Parameter Groups
In the Menu mode the parameters are divided into
groups. Selection of parameter group is effected by
means of the [<>] keys. The following parameter groups
are accessible:
Group no. Parameter group:
0 Operation & Display
1 Load & Motor
2 References & Limits
3 Inputs & Outputs
4 Special functions
5 Serial communication
6 Technical functions
7 Sensorless Control
When the desired parameter group has been selected,
each parameter can be chosen by means of the [+/-]
keys:
The 3rd line of the display shows the parameter number
and name, while the status/value of the selected
parameter is shown in line 4.
Changing Data
Regardless of whether a parameter has been selected
under the Quickmenu or the Menu mode, the procedure
for changing data is the same. Pressing the [CHANGE
DATA] key gives access to changing the selected
parameter, following which the underlining in line 4 will
flash on the display. The procedure for changing data
depends on whether the selected parameter represents a
numerical data value or a text value.
Changing a Text Value
If the selected parameter is a text value, the text value is
changed by means of the [+/-] keys.
The bottom display line shows the text value that will be
entered (saved) when acknowledgement is given [OK].
Infinitely variable change of numeric data value
If the chosen parameter represents a numeric data value,
a digit is first selected by means of the [<>] keys.
Then the chosen digit is changed infinitely variably by
means of the [+/-] keys:
The chosen digit is indicated by the digit flashing. The
bottom display line shows the data value that will be
entered (saved) when signing off with [OK].

17
Menu Structure

18
6.0 SENSORLESS OPERATION
Sensorless control is an innovative concept in glanded
circulating pumps. Pump performance and characteristic
curves for ten different speeds are embedded in the
memory of the speed controller during manufacture. This
data includes power, pressure and flow across the flow
range of the pump. During operation, the power and
speed of the pump are monitored, enabling the controller
to establish the hydraulic performance and position in the
pumps head-flow characteristic.
These measurements enable the pump to continuously
identify the head and flow at any point in time, giving ac-
curate pressure control without the need for external feed-
back signals. Patented software technology within the
controller ensures trouble-free operation in all conditions.
Incorporating the pumps hydraulic data into the controller
and removing sensors results in true integration of all
components and removes the risk of sensor failure.
6.1 DEFAULT OPERATING MODE - QUADRATIC
PRESSURE CONTROL
The default control mode for IVS Sensorless pumps
‘Quadratic Pressure Control’ where the controller is set to
control the speed according to a ‘control curve’ between
max and min flow (see above diagram). It is widely recog-
nised that fitting a differential pressure sensor at the most
remote load, across the supply piping and return piping
encompassing the valve & coil set, is the best installation
scheme for energy efficiency.
IVS Sensorless pumps can replicate this control without
the need for the remote sensor. As the flow required by
the system is reduced, the pump automatically reduces
the head developed according to the pre-set control curve.
It is often found that using a remote differential pressure
sensor to sense the pressure across a remote load could
theoretically result in loads close to the pump being un-
der-pumped. The situation would be where the load at a
loop extremity is satisfied and the control valve closes
while a load close to the pump needs full flow. The prob-
ability of this occurring is remote but it is possible. One
answer to this is to move the sensor closer to the pump
(two-thirds out in the system is a popular recommenda-
tion) although physically re-positioning the sensor at com-
missioning stage can be a costly exercise. With Sensor-
less pump control it is possible to replicate the moving of
a sensor by adjusting the head setting ‘Head Qmin’.
6.1.1 DESCRIPTION OF SETTINGS
The design duty head and flow of the pump (provided at
time of order) is defined by the controller as ’head working
point’ and ’flow working point’. The minimum head (Head
Qmin) is defined as a percentage of the head working
point. The maximum controllable head (Head Qmax) is
the head developed when the pump reaches full speed
and is calculated by the other two head settings.
6.1.2 SETTING PARAMETERS FOR QUADRATIC
PRESSURE CONTROL
 Parameter 716 - Enter the head (kPa) at design flow.
 Parameter 717 - Enter the design flow (l/s).
 Parameter 707 - Enter the minimum head requirement
(as a percentage of P716).
 Parameter 705 - Quadratic Head should be set to ’ON’.
 Parameter 798 - This is a calculated value from the
settings above and should not be changed.
6.2 CONSTANT PRESSURE CONTROL
IVS Sensorless pumps can be configured to maintain a
constant pressure in a system as the demand varies. This
effectively simulates the mounting of a differential pres-
sure sensor at, or near, the pump.
6.2.1 SETTING PARAMETERS FOR CONSTANT PRES-
SURE CONTROL
 Parameter 716 - Enter the head (kPa) at design flow.
 Parameter 717 - Enter the design flow (l/s).
 Parameter 707 - Enter the minimum head requirement
(as a percentage of P716) which will be 100% for con-
stant pressure.
 Parameter 705 - Quadratic Head should be set to ’OFF’.
 Parameter 798 - This is a calculated value from the
settings above and should not be changed.
6.3 PROPORTIONAL PRESSURE CONTROL
Where a linear reduction in head is required with reducing
flow then the quadratic curve should be turned off.

19
6.3.1 SETTING PARAMETERS FOR PROPORTIONAL
PRESSURE CONTROL
 Parameter 716 - Enter the head (kPa) at design flow.
 Parameter 717 - Enter the design flow (l/s).
 Parameter 707 - Enter the minimum head requirement
(as a percentage of P716).
 Parameter 705 - Quadratic Head should be set to
’OFF’.
 Parameter 798 - This is a calculated value from the
settings above and should not be changed.
7.0 CONTROL USING EXTERNAL FEEDBACK
(CLOSED LOOP CONTROL).
IVS Sensorless pumps can be configured (using the key-
pad) to accept a feedback signal from a remote sensor
(e.g. temperature transmitter for constant temperature).
The connection of an external device will depend on the
device itself although typical devices are 4-20mA, 2 wire
where the supply will be provided by 24VDC on terminal 6
of X101 and the output signal connected to terminal 2 of
X101.
The parameter list following this section gives typical set-
tings for closed loop control.
7.0 PARAMETER GROUPS AND DESCRIPTIONS.
Group 0 –Operation and Display.
Language/Local Control – Parameters 001, 002, 003
Not normally changed.
Active Set-up – Parameter 004
It is possible to program two separate sets of data for
controlling the inverter.
Program Set-up – Parameter 005
The active set-up can be either set-up 1, set-up 2 or can
be remotely switched between the two.
Copying of Set-ups – Parameter 006
A copy is made from the set-up selected in parameter 005
and copied to the set-up selected in parameter 006.
Copying of Set-ups Between Inverters – Parameter 007
 Connect key pad to the inverter from which the desired
set-up is to be copied.
 Select 1 in parameter 007 to upload all parameters into
the key pad.
 Connect key pad to the inverter to which the desired
set-up is to be copied.
 Select 3 in parameter 007 to download all parameters
into the inverter.
 By selecting 3 in parameter 007, copying from one size
of inverter to a different size will not affect the power
settings.
Display Scaling – Parameter 008
Multiplication factor of frequency (normally set at 1).
Display Configuration – Parameters 009-012
Allows choice of data to displayed in lines 1 and 2 of the
key pad.
Local Operations – Parameters 013-019
Not normally changed.
Group 1 – Load and Motor.
Configuration – Parameter 100
Sets the configuration under which the inverter is con-
trolled.
Set to Process Closed Loop for control via the 4-
20mA transducer feedback input set to Speed Open
Loop for Potentiometer, BMS or Sensorless control.
Motor Settings – Parameters 101-141
Are motor related parameters and are not normally
changed.
Group 2 – Reference and Limits.
Rotation Direction – Parameter 200
Sets rotation direction, normally set at 132Hz
counter clockwise.
Minimum Output Frequency – Parameter 201
Minimum output frequency is normally set at 0 to 21Hz
dependant on the mode of operation.
Maximum Output Frequency – Parameter 202
Maximum output frequency is normally set at 50Hz.
This figure should not be exceeded as the inverter could
be overloaded.
Reference Feedback – Parameter 203
Set to Min-Max and not normally changed.
Minimum Reference – Parameter 204
If operating in closed loop mode, set to minimum scale of
the feedback sensor, normally set to 0.0.
Note: Units of measurement are selected in parameter
416.
If operating in open loop mode, the units can only be dis-
played as Hz, normally set to minimum speed 0.0Hz.
Maximum Reference – Parameter 205
If operating in closed loop mode, set to maximum scale of
the sensor which is normally 4.0 Bar. In all other modes of
operation this is normally set at 50Hz.
Note : Units of measurement are selected in parameter 416.
If operating in open loop mode, the units can only be dis-
played in Hz. Normally set to a maximum speed of
50.0Hz.
Ramp Up/Down Times – Parameters 207, 208, 211,
212
Ramp up times normally set to 10 seconds.
Ramp down times normally set to 3 seconds.
Longer times should be used with higher kW motors.
Jog Frequency – Parameter 213
Normally set to 50Hz when the jog function is activated it
will override the normal reference input and run the pump
at the preset jog reference.
Reference Function – Parameter 214
Set to Sum. Not normally changed.

20
Preset Reference 1 – Parameter 215
(Set Point) if operating in closed loop mode, this parame-
ter should be set to the required set point as a percentage
of the maximum range of the feedback sensor. i.e. Sensor
range 0-4.0 Bar, set point required 2.0 Bar, parameter
would be set to 50%. If operating in open loop mode or
sensorless mode this parameter should be set to 0%.
Preset Reference 2 – Parameter 216
Set to 0% and not normally used.
Catch Up/Slow Down – Parameter 219
Set to 0% and not normally used.
Current limit for Motor – Parameter 221
This should be set to 160% except for 0.75–1.1 kW 2 pole
motors where the setting should be restricted to 120%.
Frequency Bypass Bandwidth – Parameter 229
If a skip frequency is entered at parameter 230 or 231 a
% bandwidth either side of these frequencies can be de-
fined in this parameter.
Frequency Bypass – Parameters 230-231
If resonance problems occur at particular frequencies, It is
possible to program two frequencies to be avoided.
Group 3 – Inputs and Outputs.
Inputs and Outputs – Parameters 317-340
These parameters are not normally changed.
Group 4 – Special Functions.
Special Functions – Parameters 400-446
These parameters are not normally changed.
Group 5 – Serial Communications.
Bus Address – Parameter 500
This parameter allows specification of the address for
each inverter. Used in conjunction with PLC/PC connec-
tion.
Address 0 is used for the master unit, addresses 1-126
for slave units. A repeater unit will be required if the total
number of slave units exceeds 30.
Baudrate – Parameter 501
Sets the speed of communication, set to a value that cor-
responds with the transmission speed of the PLC/PC.
Drive Control – Parameters 502-508
Allows control via terminal inputs and/or the Bus.
Bus Jog Frequency – Parameters 509-510
Activates the jog frequency via the Bus.
Protocol – Parameter 512
Selects the control word profile 0=Profidrive, 1=FC Drive.
Data Output – Parameters 513-635
Read only values of various functions.
For further information on serial communication, con-
tact Armstrong.
Group 6 – Technical Functions.
Operating Hours – Parameter 600
Readout of inverter operating time, updated hourly.
Run Hours – Parameter 601
Readout of inverter running time, updated hourly.
Power Ups – Parameter 603
Readout of number of power-ups.
Over Temperatures – Parameter 604
Readout of temperature faults.
Over Voltages – Parameter 605
Readout of over-voltage faults.
Fault Log – Parameter 615
Readout of last 10 trip codes, the lowest log number con-
tains the latest fault. (See Page 5 for Fault Code list).
Fault Log Time – Parameter 616
Readout shows total number of operating hours before
trip occurred. The lowest log number contains the latest
data.
Fault Log Value – Parameter 617
Readout shows current or voltage when the trip occurred.
Reset Hours Run Counter – Parameter 619
To reset the hours run counter in parameter 601 to zero
select 1.
Inverter Data – Parameters 620-635
Read only values of inverter identification numbers.
Group 7 – Sensorless Functions.
Sensorless Control On/Off – Parameter 700
Set to ‘On’ for Sensorless control. For all other modes of
control set to ‘Off’.
Power Error – Parameter 701
Normally set to 20W, this allows a fast but rough re-
sponse to the output Hz. Not normally changed.
Delta Frequency – Parameter 702
Normally set to 0.2Hz, as parameter 701, this allows a
fast but rough response to the output Hz. Not normally
changed.
Integral Power – Parameter 703
Normally set to 20, this allows more precise adjustments
to the output Hz. Not normally changed.
Integral Frequency – Parameter 704
Normally set to 20, as parameter 703, this allows more
precise adjustments to the output Hz. Not normally
changed.
Quadratic Head – Parameter 705
Normally set to ‘ON‘. In the ‘Off’ position a linear curve
between Min/Max head is produced. In the ‘On’ position a
quadratic curve between Min/Max head is produced.
Head Minimum – Parameter 707
Normally set to 40%. This will provide a 60% reduction in
head at ‘No Flow’ conditions. Set to 100% if a constant
head is required across the full flow range.
Power Consumption – Parameter 708
Normally set to 0 option correction factor that mainly af-
fects the head reference at high flow values.