Armstrong 4382 ivs User manual

Installation
and operating
instructions
Design Envelope 4302
and 4382 IVS vertical
in-line pumping unit
with integrated controls
File No: 94.82
Date: november 23, 2012
Supersedes: 94.82
Date: january 30, 2012

contents
1.0 Uncrating 4
1.1 Handling 4302 ivs 4
& 4382 ivs units
2.0 Installation 4
2.1 Mechanical installation 4
2.1.1 Location 4
2.1.2 Storage 4
2.1.3 Installation 4
2.1.4 Pump piping – general 5
2.1.5 Alignment 5
2.1.6 Starting pump 5
2.1.7 General care 6
2.1.8 Lubrication 6
2.1.9 System cleanliness 6
3.1 Enclosure rating 10
3.2 Ambient temperature 10
4.0 Electrical installation 10
4.1 Ground leakage current 11
4.2 Start/stop of pump 11
4.3 Additional motor protection 11
4.4 Supply voltage 11
4.5 Supply fusing 11
4.6 Grounding and it mains 12
4.7 Relay connections 13
4.8 Electrical installation 14
and control connections
4.8.1 Access to terminals 15
4.8.2 Control terminals 15
4.8.3 Connection examples 16
4.8.4 Remote lcp keypad wiring 17
5.0 Programming, monitoring 18
and diagnotics
5.1 glcp functions and operation 18
5.2 Indicator lights (leds) 19
5.3 Control keys 19
5.4 Programming 20
5.4.1 Parameter selection 20
5.4.2 Changing data 21
6Sensoreless operation 21
6.1 Default operating mode – 21
quadratic pressure control
6.1.1 Settings for quadratic 22
(control curve) pressure control
6.2 Constant pressure control 23
6.2.1 Settings for constant 23
pressure control
6.3 Changing control modes 23
6.3.1 Change to external sensor 23
control
6.3.2 Change to open loop (bas) 23
control
6.3.3 Change to sensorless 23
control
7.0 Warnings and alarms 23
7.1 Fault messages 24
8.0 Acoustic noise and vibration 27
table 1 Alarm/warning code list 28
table 2 ivs 102 parameter settings 28

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
4
1.0 uncrating
Armstrong dualArm Design Envelope 4302 ivs and 4382 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 im-
mediately. 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 controls. 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 and 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 sur-
face and re-position the straps, if necessary, to ensure safe and
damage free transportation into the pipe installation
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. Rust-
proofing or packing the casing with moisture absorbing mate-
rial 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 and 4382 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 9)
• Pipe supported at the ceiling, with the dualArm free-standing
and mounted with an Armstrong Suction Guide & Flo-Trex
valve. (See Figs. 2.2 & 2.3 on page 9)
• Piping supported at ceiling with additional floor mounted
supports under Armstrong Suction Guide and Flo-Trex Valve
(See Fig. 2.4 on page 9)
• Floor mounted saddle supports (See Fig. 2.5 on page 10)
• Where required, additional floor support may be obtained
as shown in Fig. 2.5. Note that the pump must not be rigidly
4382 ivs 4302 ivs

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
5
attached either to the plate or to the block. Leave a V" (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 10) 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.
important
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.
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 el-
bows.
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.
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. V" (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
4or 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 pres-
sure 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.
caution
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.
important
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 se-
rious and dramatic damage to the pump and surrounding area.
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 and 4382 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.

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
6
Start the pump with the discharge valve closed and the suc-
tion valve open, then gradually open the discharge valve when
the motor is at operating speed. The discharge valve may be
“cracked” or open slightly at start up to help eliminate trapped
air.
When stopping the pump: Close the discharge valve and
de- energize the motor.
caution
Centrifugal pump rotation is generally “clockwise”
when viewing from the motor end.
Check rotation arrow prior to operating the unit.
2.1.7 general care
Vertical In-Line pumps are built to operate without periodic
maintenance. A systematic inspection made at regular inter-
vals, 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 100°f/40°c).
• 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).
warning
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.
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
Mechanical seal
Mechanical seals require no special attention. The mechanical
seal is flushed from discharge of the pump casing on 4302 a n d
towards the suction on 4382. Seal environmental controls,
installed in flush lines, such as filters and separators, will pro-
long 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. (For 4302 see file 43d.88 and for 4382 see file
43d.81 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 treat-
ment are all detrimental to the pump internals and sealing
arrangement.
Proper operation cannot be guaranteed if the above conditions
are not adhered to.
note:
Particular care must be taken to check the following before the
pump is put into operation:
aPump primed?
bAlignment correct?
cRotation ok?
d Lubrication ok?
ePipe work properly supported?
fVoltage supply ok?
gOverload protection ok?
hIs the system clean?
iIs the area around the pump clean?
jPipe work properly supported?
warranty
Refer to Armstrong General Terms and Warranty sheet. Con-
tact your local Armstrong representative for full information.

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
7
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 run-
ning.
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
1Stop the pump to be serviced.
2Close and lock the suction and discharge valves: as per
instructions below.
3Ensure seal flushline interconnection valve is closed and
drain the isolated casing.
4Service 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.
2Fill the dry casing with system fluid by opening the seal flush-
line interconnecting valve and the air vent fitting.
3Allow the pressure to equalize in the two casings, if neces-
sary, by opening seal flush line interconnected valve.
4Unlock the discharge valve as per instructions below.
5Unlock the suction valve as per instructions below.
6Close the seal flushline interconnect valve and restart pump.
note:
Keep hands and tools away from locked suction valve arm, as
the dierential pressure may cause the arm to rotate quickly
with force when unlocked.
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.
note:
Ensure the pump to be isolated is not operating before attempt-
ing to release the locking mechanism. Failure to do so may
result in injury to the operator and/or damage to the pump.
Locking
1Loosen discharge side set screw (11) to relea s e th e l o ck ing
handle (3).
2Rotate 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).
3Rotate discharge valve shaft (16) towards the pump to be
isolated. The orientation of the shaft is indicated by the cen-
ter pin on the locking arm (4).
4Raise 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.
5Tighten set screw (11) to lock the locking handle (3) in posi-
tion.
This handle should not be rotated past the vertical
position.
note:
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.
Unlocking
1Open the interconnecting valve on the seal flushline to
pressurize the serviced pump and vent air through bleeder
valve on series 4302 and 4382. Close these valves once the
pressure is equalized and air removed.
2Loosen set screw (11) and lower locking handle (3) to the
horizontal position, secure with set screw (11).
3Rotate valve to center position so that the center pin of the

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
8
locking arm (4) locates in the recess on the locking handle (3).
4Loosen 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 oper-
ated isolation valve. This valve is not designed to automatically
pivot as the discharge flappers do.
warning:
Care should be taken when performing procedures (3) and (4)
below. Read the following instructions carefully.
Locking
1Loosen suction side set screw (11) to release the locking
handle(3).
2Rotate 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).
3Rotate 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).
4Loosen 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.
5Tighten set screw (11) to secure the locking handle (3) in
position
note:
The locking handle (3) should only be rotated towards the
pump stopped for service. The dualarm suction valve is de-
signed 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 sucient force to injure the
operator and/or cause damage to the pump. Do not attempt to
circumvent this safety feature.
warning:
Care should be taken when performing procedures (3)
and (4) below. Read the following instructions carefully.
Unlocking
1Open the interconnecting valve on the seal flushline to
pressurize the serviced pump and vent air through bleeder
valve on series 4302 and 4382. Close these valves once the
pressure is equalized and air removed.
2Loosen set screw (11) and lower locking handle (3) to the
horizontal position, secure with set screw (11).
3Rotate valve to center position so that the center pin of the
locking arm (4) is located in the recess on the locking handle
(3).
4Loosen set screw (11) and raise locking arm (3) t o t h e v e r t i c a l
position, locking the center pin in the locking arm recess,
secure with set screw.
note:
Keep hands and tools away from suction valve locking arm
when freed by locking handle as dierential pressure may
cause arm to rotate quickly with force when unlocked.
fig. 1.1 Valve illustration (3", 4" and 6")
4
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).

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
9
1
3
1
fig. 1.2 Suction valve fig. 1.3 Discharge valve
fig. 1.4 Valve illustration (8")
fig. 1.5 Suction valve fig. 1.6 Discharge valve
fig. 2.1 Hanger supported pipe mounted
fig. 2.2 Pipe mounted supported at ceiling
System inlet System outlet
Recommended field
pressure gauge piping
arrangement Flo-Trex valve
Split
coupler
Flush line
Drain connection
Suction
guide
Hangers support the weight
of the filled piping, pumps
and fittings
Pipe hanger (typ.)
see specification for
size and type
Pet cock
(typ.)
2' or 3'
height above
finished floor
Fig. 2.3 Discharge elbow for minimum footprint
Drain connection
Suction guide
System inlet
Recommended field
pressure gauge piping
arrangement
Flo-Trex valve
Hangers support the
weight of the filled piping,
pumps and fittings
Pipe hanger (typ.)
see specification
for size and type
System outlet
Split coupler
Flush line
4
This pump suction is now closed.
(Locked when handle is elevated
and secured).
Normal operation
Normal operation
Normal operation
Normal operation
This pump discharge is now
closed. (Locked when handle is
elevated and secured).
3
1
1

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
10
fig. 2.4 With additional pipe supports
Drain connection
Suction guide
Neoprene
isolation pad
System inlet
Recommended field
pressure gauge
piping arrangement
Pipe support
Flo-Trex valve
Pet cock
(typ.)
Pipe hanger (typ.)
see specification
for size and type
System outlet
Split
coupler
Flush line
2' or 3'
height above
finished floor
Hangers support the weight
of the filled piping, pumps
and fittings
fig. 2.5 Floor saddle support
fig. 2.6 Additional floor support
GAP
fig. 2.7 Not recommended
fig. 2.8 Tapped collection well on Series 4302ivs
Series 4302 ivs seal
leaks or condensate
drain hole. Plumb to
drain for area
cleanliness
integrated controls
3.1 enclosure rating
The standard enclosure rating for Series 4302 ivs
and 4382 ivs integrated controls is nema/ul type 12.
If the pump is to be installed in a wet or dusty
environment then a higher enclosure rating may be
required (contact Armstrong)
3.2 ambient temperature
To avoid the inverter unit getting overheated, the
ambient temperature is not to exceed 133°f (45°c).
Operating in higher ambient temperatures will require
derating of the inverter.

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
11
4.0 electrical installation
All ele c tric a l c o n nec tions sho u l d b e ca r r i e d ou t by
a qualified and authorized electrician in accordance
with local site regulations and the latest issue of the
iee regulations.
safety, risk of death
Before removing the controls cover, the system must
be disconnected from the mains supply. After switch-
ing o, wait for at least 15 minutes for the capacitors
to discharge before opening the cover.
caution
High voltage testing (Megging) of the motor/ controls
may cause damage to the electronic components and
therefore should not be carried out
4.1 ground leakage current
Ground leakage current is primarily caused by the
capacitance between motor phases and the motor
frame. The rfi filter contributes additional leakage
current, as the filter circuit is connected to ground
through capacitors.
The size of the leakage current to the ground depends on the
following factors, in order of priority:
1Switching frequency
2Motor grounded on site or not
The leakage current is of importance to safety during han-
dling / operation of the ivs pump if (by mistake) the on-board
inverter has not been grounded.
Since the leakage current is >3.5ma(approx 4-20ma),
reinforced Grounding 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 con-
tent (dc) in the fault current (three-phase bridge rectifier)
• Suitable for power-up with short charging current to Ground
• Suitable for a high leakage current
4.2 start / stop of pump
The number of starts/stops via the mains voltage must not
exceed one-time per minute.
If a higher number of starts/stops is required then the start/
stop digital input must be used (mains voltage directly con-
nected). This is the preferred method of starting and stopping
ivs pumps.
The three 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 (for over-current and short-circuit
protection), no additional overload or over-temper-
ature protection is required (i.e. thermal overloads).
Protection features include:
• Mains phase loss
• Over voltage
• Under voltage
• Electronic thermal motor protection
• Short circuit on motor terminals
• Ground fault on motor terminals
• Over temperature
4.4 supply voltage
The supply voltage details can be found on the inverter name-
plate. Please ensure that the unit is suitable for the electri-
cal supply on which it is to be used. The mains supply for ivs
pumps is as follows:
3 × 200-240v +/-10%
3 × 380-480v +/- 10%
3 × 525-600v +/- 10%
Supply frequency - 50/60hz
4.5 supply fusing
Branch circuit protection
In order to protect the installation against electrical and fire
hazard, all branch circuits in an installation, switch gear, ma-
chines etc., must be short-circuit and over-current protected
according to the national/international regulations.

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
12
Short circuit protection
The inverter must be protected against short-circuit to avoid
electrical or fire hazard. Armstrong recommends using the fuses
detailed in the separate ivs102 Operating Instructions to pro-
tect service personnel or other equipment in case of an internal
failure in the unit. The frequency converter provides full short
circuit protection in case of a short-circuit on the motor output.
4.6 grounding and it mains
The ground connection cable cross section must be
at least 10 mm2or two rated mains wires terminated
separately according to en 50178 or iec 61800-5-1
unless national regulations specify dierently. Always
comply with national and local regulations on cable
cross sections.
The mains is connected to the main disconnect
switch if this has been included.
Check the mains voltage corresponds to the mains
voltage of the frequency converter name plate.
it mains
Do not connect frequency converters with rfi-filters
to mains supplies with a voltage between phase and
earth of more than 440v for 400v converters and
760v for 690v converters. For 440v it mains and delta earth
(grounded leg), mains voltage may exceed 440v between
phase and earth. For 690v it mains and delta earth (grounded
leg), mains voltage may exceed 760v between phase and earth.
fig. 2 Terminals for mains and grounding
Three phase
power input
fig. 3 Mains and grounding connections for a5 units
(200-240v – 5hp and below, 380-480v / 525-600v -
10hp and below)
95
fig. 4a Mains and grounding connections for b1 and b2 units
(200-240v – 7.5 to 20hp, 380-480v – 15 to 40hp, 525-600v – 15
to 50hp)
95
fig. 4b Mains and grounding connections for c1 and
c2 units (200-240v – 25 to 60hp, 380-480v – 50 to 125hp, 525-600v
– 60 to 125hp)
95
91
L1
92
L2
93
L3
91 (l1)
(l2)
(l3)
pe
92
93
95

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
13
4.7 relay connections
The relays on the ivs are configured as follows:
relay 1 – running
• Terminal 01: Common
• Terminal 02: Normal Open 240v ac
• Terminal 03: Normal Closed 240v ac
relay 2 – alarm
• Terminal 04: Common
• Terminal 05: Normal Open 400v ac
• Terminal 06: Normal Closed 240v ac
fig. 5 Relay contact details
04
05
06
01
02
03
240v ac, 2a
400v ac, 2a
240v ac, 2a
Relay 1
Relay 2
The following illustrations identify the location of the relays
within specific inverter sizes:
The illustrations in figures 6, 7 and 8identify the location of the
relays within specific inverter sizes:
fig. 6 Relay connection: terminals for a5, b1 and b2 units
fig. 7 Relay connection terminals for c1 and c2 units

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
14
4.8 electrical installation and control connections
fig. 8 Diagram showing all electrical connections
*Note: terminal 37 is not available on ivs sensorless pumps

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
15
4.8.1 access to terminals
Remove front-cover to access control terminals. When
replacing the front cover, please ensure proper fastening by
applying a torque of 2 Nm.
4.8.2 control terminals
With reference to figure 9:
fig. 9 Control Connections
Control terminal functions and factory settings are as follows:
terminal no. type / description factory setting
1,2,3 Relay 1 Running
4,5,6 Relay 2 Alarm
12 Supply +24v dc
13 Supply +24v dc
18 Digital Input Start
19 Digital Input Pump Operating
Mode
20 Common ok
27 Digital Input Low Water Interlock
29 Digital Input No Operation
32 Digital Input No Operation
33 Digital Input No Operation
37 Digital Input No Operation
42 Analogue Out-
put
Output Frequency
(4-20mA - 0-100Hz)
53 Analogue Input Reference (0-10v)*
54 Analogue Input Feedback (0-10v)*
*Note that Analogue inputs ai53 and ai54 can be either Voltage
(0-10v) or Current (4-20mA) input and by default both inputs
are set to Voltage. Switches s201 and s202 (see figure 8) are
used to configure the analogue inputs as follows:
s201 (ai53) off = Voltage, on = Current
s202 (ai54) off = Voltage, on = Current
Inserting Cables into Control Terminals
iStrip 10mm of insulation from the cable:
ii Insert a suitable terminal screwdriver
as shown and then push the cable into
the terminal.
iii Remove the terminal screwdriver and
check the terminal has gripped the cable
by gently pulling it.
Note:
Terminal plugs can be easily removed
for improved access when making
connections.
2
1
10mm
10mm
eference to figure 10:
e 10. Control Connections
110-way plug for
digital i/0
23-way plug for
rs485 bus
36-way plug for
analogue i/0
4usb connection

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
16
4.8.3 connection examples
ivs Sensorless pumps can be configured in four main ways:
i Sensorless
ii Closed loop – with feedback sensor
iii Constant Curve Mode – Potentiometer Control
iv Constant Curve Mode – bms signal
iv.i Full Speed Override
i sensorless
ivs sensorless pumps are factory configured to be
connected as shown below.
ii closed loop – with sensor feedback
To control the pump based on a 4-20mA feedback signal from
a sensor use the following connection.
12 (+24v )
20 (0v )
18 (d in)
Start Signal
Output Fr equency
4-20mA Analog ue Out
Running Output
Alarm Output
19 (d in)
29 (d in)
32 (d in)
33 (d in)
50 (10v)
53 (Ain)
54 (Ain)
55 (0v )
42 (Aout)
39 (Aout)
2 (r1 n/o)
3 (r1 n/c)
1 (r1 com)
5 (R2 N/ O)
6 (R2 N/C)
4 (R2 COM)
24v
12 (+24v )
20 (0v )
18 (d in)
Start Signal
Output Frequency
4-20mA Analogue Out
Running Output
Alarm Output
19 (d in)
27 (d in)
29 (d in)
32 (d in)
33 (d in)
50 (10v)
53 (Ain)
54 (Ain)
55 (0v )
42 (Aout)
39 (Aout)
2 (r1 n/o)
3 (r1 n/c)
1 (r1 com)
5 (R2 N/O)
6 (R2 N/C)
4 (R2 COM)
Pressure Sensor
(0-10 bar / 4 -20ma)
Feedback from Sensor
4-20mA - Input t54
Power Supply (24 vdc)
for sensor t13=24v

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
17
iii constant curve mode – potentiometer
To control the pump based on a 0-10v potentiometer signal
use the connections below.
iv constant curve mode – bms signal
When 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.
iv.i constant curve mode - bms signal
It may be required to run the pump at full speed without auto-
matic speed control (eg during system commissioning). This
can be achieved without programming changes by making the
connections below.
4.8.4 remote lcp keypad wiring
For large ivs units with remote lcp keypad, see wiring
arrangement below.
lcp wiring arrangement
terminal wire color
1Green
2Brown
3Red
4Yellow
5Black
6Orange
7Blue
8Purple
9Grey
12 (+24v )
20 (0v )
18 (d in)
Start Signal
Running Output
Alarm Output
19 (d in))
27 (d in))
29 (d in))
32 (d in))
33 (d in))
50 (10v)
53 (Ain)
54 (Ain)
55 (0v )
42 (Aout)
39 (Aout)
2 (r1 n/o)
3 (r1 n/c)
1 (r1 com)
5 (r2 n/o)
6 (r2 n/c)
4 (r2 com)
0-10v Derived from 1k
Potentiometer into Input
t53 (common t55)
Output Frequency
4-20mA Analogue Out
2 (r1 n/o)
3 (r1 n/c)
1 (r1 com)
5 (r2 n/o)
6 (r2 n/c)
4 (r2 com)
0-10v Signal from bms
Input t53 (common t55)
Output Frequency
4-20mA Analogue Out
12 (+24v )
20 (0v )
18 (d in)
Start Signal
Running Output
Alarm Output
19 (d in)
27 (d in)
29 (d in)
32 (d in)
33 (d in)
50 (10v)
53 (Ain)
54 (Ain)
55 (0v )
42 (Aout)
39 (Aout)
2 (r1 n/o)
3 (r1 n/c)
1 (r1 com)
5 (r2 n/o)
6 (r2 n/c)
4 (r2 com)
Output Frequency
4-20mA Analogue Out
12 (+24v )
20 (0v )
18 (d in)
Start Signal
Running Output
Alarm Output
19 (d in)
27 (d in)
29 (d in)
32 (d in)
33 (d in)
50 (10v)
53 (Ain)
54 (Ain)
55 (0 v)
42 (Aout)
39 (Aout)
Link 10vdc (t50 ) into
Analogue Input t5 3

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
18
5 programming, monitoring
and diagnostics
ivs pumps incorporate an integrated graphical local control
panel (glcp).
5.1 glcp functions and operation
The glcp is divided into four functional groups:
1
2
3
4
b
a
c
1Graphical display with status lines.
2Menu keys and indicator lights (leds) – selecting mode,
changing parameters and switching between display func-
tions.
3Navigation keys and indicator lights (leds).
4Operation keys and indicator lights (leds).
Graphical display:
The lcd-display is back-lit with a total of six alpha-numeric
lines. All data is displayed on the lcp which can show up to fiv e
operating variables while in Status mode.
Display lines:
a Status line: Status messages displaying icons
and graphics.
bLine 1–2: Operator data lines displaying data and variables
de-fined or chosen by the user. By pressing the Status key,
up to one extra line can be added.
c Status line: Status messages displaying text.
The display is divided into three sections:
Top section (a) shows the status when in status mode or up
to two variables when not in status mode and in the case of
alarm/warning.
The number of the Active Set-up (Sensorless mode being setup
1) is shown.
The Middle section (b) shows up to five variables with related
unit, regardless of status. In case of alarm/warning, the warn-
ing is shown instead of the variables.
The Bottom section (c) always shows the state of the inverter
in Status mode.
It is possible to toggle between three status read-out displays
by pressing the Status key.
Operating variables with dierent formatting are shown in each
status screen — see below.
Status display I:
This read-out state is standard after start-up or initialisation.
Use Info to obtain information about the value/measurement
linked to the displayed operating variables (1.1, 1.2, 1.3, 2 and 3).
See the operating variables shown in the display in this illustra-
tion. 1.1,1.2 and 1.3 are shown in small size. 2and 3are shown in
medium size.
Status display II:
See the operating variables (1.1, 1.2, 1.3 and 2) shown in the
display in this illustration.
In the example, Speed, Motor current, Motor power and Fre-
quency are selected as variables in the first and second lines.
1.1, 1.2 and 1.3 are shown in small size. 2is shown in large size.
Display Contrast Adjustment
Press Status and [] for darker display
Press Status and [] for brighter display

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
19
5.2 indicator lights (leds)
If certain threshold values are exceeded, the alarm and/or
warning led lights up. A status and alarm text appear on the
control panel. The on led is activated when the frequency con-
verter receives power from mains voltage, a dc bus terminal, or
an external 24v supply. At the same time, the back light is on.
• Green led/on: Control section is working.
• Yellow led/warn.: Indicates a warning.
• Flashing Red led/alarm: Indicates an alarm.
5.3 control keys
Menu keys
The menu keys are divided into functions. The keys below the
display and indicator lamps are used for parameter set-up,
including choice of display indication during normal operation.
Status
Indicates the status of the frequency converter and/or the
motor. Three dierent readouts can be chosen by pressing the
Status key: five line readouts, four line readouts or Smart Logic
Control.
Use Status for selecting the mode of display or for changing
back to Display mode from either the Quick Menu mode, the
Main Menu mode or Alarm mode. Also use the Status key to
toggle single or double read-out mode.
Quick Menu
Allows quick set-up of the inverter by access to a limited
number of parameters. Quick Menu does not include all the
parameters that may need to be changed when utilising Sen-
sorless control and it is therefore recommended that parameter
changes are made in Main Menu mode.
Main Menu
Is used for programming all parameters.
Alarm Log
Displays an Alarm list of the five latest alarms (numbered a1-
a5). To obtain additional details about an alarm, use the arrow
keys to manoeuvre to the alarm number and press ok. Informa-
tion is displayed about the condition of the frequency converter
before it enters the alarm mode.
The Alarm log button on the lcp allows access to both Alarm
log and Maintenance log.
Back
Reverts to the previous step or layer in the navigation structure.
Cancel
Last change or command will be cancelled as long as the dis-
play has not been changed.
Info
Displays information about a command, parameter, or function
in any display window. Info provides detailed information when
needed.
Navigation Keys
The four navigation arrows are used to navigate between the
dierent choices available in Quick Menu, Main Menu and
Alarm Log. Use the keys to move the cursor.
OK
Is used for choosing a parameter marked by the cursor and for
enabling the change of a parameter.
Operation Keys for local control are found at the bottom of the
control panel.
Hand On
Enables control of the pump via the glcp. It is possible to enter
the pump speed data by means of the arrow keys.

installation &
operating instructions
Design Envelope 4302 ivs and 4382 ivs vertical
in-line pumping unit with integrated controls
20
The low water device input must be made for the
pump to start in either hand mode or auto mode.
O
Stops the pump.
Auto On
Enables the pump to be controlled via the control terminals
and/or serial communication. When a start signal is applied on
the control terminals the pump will start.
For the pump to operate in either Sensorless mode or
any other automatic control mode it is necessary to
have pressed the Auto On button.
Reset
Is used for resetting the frequency converter after an alarm
(trip).
5.4 programming
Select the Main Menu mode by pressing the Main Menu key.
The below read-out appears on the display. The middle and
bottom sections on the display show a list of parameter groups
which can be chosen by toggling the up and down buttons.
Each parameter has a name and number which remain the
same regardless of the programming mode. In the Main Menu
mode, the parameters are divided into groups. The first digit of
the parameter number (from the left) indicates the parameter
group number.
All parameters can be changed in the Main Menu. However,
depending on the choice of configuration (Par.1-00 Configura-
tion Mode), some parameters can be hidden.
5.4.1 parameter selection
In the Main Menu mode, the parameters are divided into
groups. You select a parameter group by means of the naviga-
tion keys.
The following parameter groups are accessible:
group
no.
parameter
group
group
no.
parameter
group
0Operation/dis-
play
13 Smart Logic
1Load/motor 14 Special functions
2Brakes 15 fc information
3References/
ramps
16 Data readouts
4Limits/warnings 18 Data readouts 2
5Digital in/out 20 Drive closed loop
6Analog in/out 21 Ext. closed loop
8Com. and options 22 Application functions
9Profibus 23 Time-based functions
10 can Fieldbus 25 Cascade controller
11 LonWorks 26 Analog i/0 option
mcb 109
After selecting a parameter group, choose a parameter by
means of the navigation keys.
The middle section on the display shows the parameter number
and name as well as the selected parameter value.