Armstrong Design Envelope 4300 User manual

Design Envelope
4300 & 4380
Vertical In-line
Pumping Unit
Installation and
operating instructions
File No: 94.81
Date: november 09, 2016
Supersedes: 94.81
Date: february 03, 2016

5.3 Control keys 22
5.4 Programming 23
5.4.1 Parameter selection 23
5.4.2 Changing data 24
6.0 Sensorless operation 24
6.1 Default operating mode – 25
Quadratic pressure control
6.1.1 Settings for quadratic
(control curve) pressure
control 25
6.2 Constant pressure control 25
6.2.1 Settings for constant
Pressure control 26
6.3 Changing control modes 26
6.3.1 Change to external
sensor control 26
6.3.2 Change to open loop
(bas) control 26
6.3.3 Change to sensorless
control 26
6.4 Special Application Procedures 26
6.4.1 2-way bypass valve
control 26
6.4.2 Maximum flow control 28
6.4.3 Flow limit breach closes
a dry-contact relay 29
6.4.4 Minimum flow control 29
6.4.5 Multiple sensor control 30
6.4.6 Motor pre-heat
application 31
6.4.7 Start standby pump by
falling sensor reading 33
6.4.8 Start standby by system
contact opening 34
7.0 Warnings & alarms 36
7.1 Fault messages 36
8.0 Acoustic noise & vibration 39
table 1 Alarm/warning code list 40
table 2 ivs 102 parameter settings 42
contents
1.0 Introduction 4
1.1 Instructions for safe use 4
1.2 Temperature 4
1.4 Vibration levels 5
1.5 Storage 5
1.6 Uncrating 5
1.7 Handling Design Envelope
4300 & 4380 units 5
2.0 Installation 6
2.1 Location 6
2.2 Installation 6
2.3 Pump piping – general 7
2.4 Alignment 8
2.5 Starting pump 8
2.6 General care 8
2.7 Lubrication 9
2.8 System cleanliness 9
3.1 Enclosure rating 13
3.2 Ambient temperature 13
4.0 Electrical installation 13
4.1 Ground leakage current 13
4.2 Start/stop of pump 13
4.3 Additional motor protection 13
4.4 Supply voltage 14
4.5 Supply fusing 14
4.6 Grounding & it mains 14
4.7 Relay connections 15
4.8 Electrical installation
& control connections 15
4.8.1 Access to terminals 18
4.8.2 Control terminals 18
4.8.3 Connection examples 19
4.8.4 Remote lcp keypad
wiring 20
5.0 Programming, monitoring 20
& diagnotics
5.1 glcp functions & operation 21
5.2 Indicator lights (leds) 22

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
4
1.0 introduction
This document contains specific information regarding the safe
installation, operating and maintenance of the Armstrong Design
Envelope pumps should be read and understood by installing,
operating and maintenance personnel. The equipment supplied
has been designed and constructed to be safe and without risk to
health and safety when properly installed, operated and main-
tained. The instructions following must be strictly adhered to. If
clarification is needed on any point please contact Armstrong
quoting the equipment serial number.
1.1 instructions for safe use
No installation of this equipment should take place
unless this document has been studied and understood.
Handling, transportation and installation of this equip-
ment should only undertaken by trained personnel with proper use
of lifting equipment. See later diagrams for lifting advice. Refer to
the pump nameplate for pump speed, pressure and temperature
limitations. The limits stated must not be exceeded without
written permission from Armstrong.
1.2 temperature
Install the Design Envelope unit with adequate access
for routine maintenance. Adequate space, particularly
at the fan inlet 2" (50 mm), is necessary to facilitate
airflow. Where several Design Envelope units are installed in close
proximity, care must be taken to ensure that there is no re-circula-
tion of exhausted warm air.
Where under normal operating conditions the limit of 68°c/155°f
(Restricted Zone) for normal touch, or 80°c/176°f(Unrestricted
Zone) for unintentional touch, may be experienced, steps should
be taken to minimize contact or warn operators/users that normal
operating conditions will be exceeded. In certain cases where
the temperature of the pumped liquid exceeds the above stated
temperature levels, pump casing temperatures may exceed
100°c/212°fand not withstanding pump insulation techniques
appropriate measures must be taken to minimize risk for
operating personnel. The ambient temperature for standard
motors must be no greater than 40°c/104°f.
1.3 noise levels
Typical Pumping Unit Sound Pressure Level, Decibels, A-Weighted, at 1 m (3ft.) from unit.
1200 rpm 1800 rpm 3600 rpm
frame
designation
odp tefc odp tefc odp tefc
hp db-a hp db-a hp db-a hp db-a hp db-a hp db-a
140 0.75 - 1 59 0.75 - 1 58 1 - 3 64 1 - 2 64 1.5 - 3 70 1.5 - 2 79
180 1.5 - 2 61 1.5 - 2 61 3 - 5 66 3 - 5 68 5 - 7.5 74 3 - 5 82
210 3 - 5 66 3 - 5 65 7.5 - 10 70 7.5 - 10 73 10 - 15 76 7.5 - 10 85
250 7.5 - 10 70 7.5 - 10 69 15 - 20 74 15 - 20 78 20 - 25 78 15 - 20 88
280 15 - 20 75 15 - 20 74 25 - 30 74 25 - 30 82 30 - 40 80 25 - 30 89
320 25 - 30 77 25 - 30 77 40 - 50 78 40 - 50 83 50 - 60 83 40 - 50 94
360 40 - 50 80 40 - 50 80 60 - 75 80 60 - 75 89 75 - 100 88 60 - 75 95
400 60 - 75 82 60 - 75 84 100 - 125 83 100 92 125 - 150 92 100 96
440 100 - 125 85 100 - 125 88 150 - 200 87 125 - 150 96 200 - 250 95 125 - 150 98
440 100 - 125 85 100 - 125 88 150 - 200 87 125 - 150 96 200 - 250 95 125 - 150 98

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
5
1.4 vibration levels
Armstrong Vertical In-Line pumps are designed to meet vibration
levels set by Hydraulic Institute Standard hi Pump Vibration 9.6.4.
Standard levels are as detailed below:
0.28
0.24
0.20
10 100 10001
0.16
0.12
0.08
0.04
0
input power @ test conditions– hp
vibration – ins/sec rms, unfiltered
1.5 storage
Pumps not immediately placed into service, or removed from
service and stored, must be properly prepared to prevent exces-
sive rusting. Pump port protection plates must not be removed
until the pump is ready to connect to the piping.
Rotate the shaft periodically (at least monthly) to keep rotating
element free and bearings fully functional.
For long term storage (longer than three months), 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 buildup or the possibility of freezing. Be sure to rein-
stall 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.
1.6 uncrating
Armstrong Vertical 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
and hooks 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.
1.7 handling design envelope 4300 &
4380 units
To handle Design Envelope 4300 and 4380 units from shipment,
secure the pallet following uncovering the unit, then placestraps
behind the integrated controls (around the motor feet) and
carefully lift the pumping unit to stand the pump vertically upright.
Lift only suciently to remove the pallet, then lower onto a flat
surface. The pump and motor unit will free-stand on the casing
ribs.Extra care is required to ensure the integrated controls do not
get damaged during lifting and installation.
7.11
6.10
5.08
7.5 75 7500.75
4.06
3.04
2.03
1.01
0
input power @ test conditions–kw
vibration – mm/sec rms, unfiltered
vertical in - line
xy
a

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
6
For Design Envelope 4300 units, remove the coupling guard and
insert lifting straps through the pump/motor pedestal on either
side of the coupling. For Design Envelope 4380 units, remove
the motor eye-bolt and install a swivel hoist ring tied to a lifting
strap. Place secondary lifting straps around the motor feet (and/
or spacers). As the lifting device is engaged (Using a spacer bar
if necessary) and the straps tighten ensure no part of the strap-
ping 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 installation.
4300 4380
Remove coupling guard and
place lifting straps on each
side of coupling, use spacer
bar if necessary to protect the
integrated controls and motor
fan cover.
Remove the motor eye-bolt
and install a swivel hoist
ring tied to a lifting strap.
Place secondary lifting straps
securely around motor feet
(and/or spacers).
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 serious and dramatic damage to the pump and
surrounding area.
2.0 installation
2.1 location
In open systems, 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.
In closed systems, where possible, the pumps should be installed
immediately downstream of the expansion tank /make-up connec-
tion. This is the point of zero pressure change and is necessary for
eective pump operation. Do not install more than one expansion
tank connection into any closed hydronic system.
Electric motor driven pumps should not be located in damp or
dusty location without special protection.
Airflow into the motor and/or motor fan should not be obstructed.
It is good practice to leave sucient space around equipment for
maintenance and service needs. If the ivs102 controls are sup-
plied with integral disconnect switches, 36ins / 1meter clearance
may be required in front of the controls to meet local electrical
codes.
2.2 installation
When installing vertical in-line pumps, an important consideration
to accrue full added-value from the pump design is to ensure that
the pump is pipe-mounted and free to ‘float’ with any movement,
expansion and contraction of the piping. Should any vertical in-line
pump use supports to the structure it is imperative that no pipe
strain is imposed on the pump flanges. Tell-tale pieces of equip-
ment such as springs or ‘wae’ style neoprene isolation pads
that distort with pressure to indicate added piping weight, should
be used under pump supports should the pump not be truly pipe
mounted.
Design Envelope 4300 and Design Envelope 4380 cannot be
mounted with shafts in the horizontal position.
Various installation arrangements are detailed on Pages 9–12
All Design Envelope 4300 pumps contain a tapped hole in the mo-
tor bracket above the discharge flange to drain condensate buildup
of seal leakage. (Fig. 2.14)
2.2.1
Vertical In-Line pumps may be installed directly in the system
piping with no additional support. Pipe hangers are simply sized
for the additional weight of the pumping unit. Many pumps are
installed in this manner and can be mounted at sucient height to
take zero floor space. (Fig. 2.1)
2.2.2
Piping in many mechanical rooms is hung close to the ceiling
and larger pumps are mounted near ground level for ease of
maintenance. Fig 2.2 illustrates such an arrangement with the
piping supported at the ceiling and the vil unit installed with an
Armstrong Suction Guide and Flo-Trex valve. Many very large vil
pumps are installed in this manner.
2.2.3
Should additional space saving be required the discharge spool
piece may be replaced by a long-radius elbow.

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
7
2.2.4
Fig 2.4 illustrates a similar arrangement to Fig 2.2 with additional
floor mounted pipe-stools isolated from the structure by ‘wae’
style neoprene isolation pads under the Armstrong Suction Guide
and Flo-Trex valve.
2.2.5
Floor mounted saddle supports (Fig. 2.5) are typical for condenser
water pumps where cooling tower base is at the mechanical room
elevation.
2.2.6
Where required, additional floor support may be used as shown
in Fig. 2.6. Note that the pump should not be rigidly attached to
the column. Leave a small gap between pump and column or
install a ‘wae’ isolation pad under the pump. It is critical that
piping be installed in such a manner that the pump does not
become a pipe support.
2.2.7
Fig. 2.7 illustrates stanchion plates at the pump inlet and outlet
ports that may be supplied for installation convenience. Isolation
pads must be used under the legs and monitored as pipe hang-
ers are adjusted to ensure the pump flanges are not supporting
the piping. Bolting to the floor or housekeeping pad is not recom-
mended. If the stanchions are bolted down the bolts must be
isolated from the stanchion or an inertia base and flexible pipe
connectors used.
2.2.8
Fig. 2.8 illustrates installations with stanchion plates for seismical-
ly active regions. Seismically rated isolation pads or snubbers with
bolts isolated from the stanchion plates are installed to restrain the
pump during a seismic event. Pipe hangers carry the weight of the
equipment as seismic components are designed only to restrain
the equipment during a seismic event.
2.2.9
Many Vertical In-Line pumps are piped successfully into grooved
piping systems. In-line pumps are supported well by grooved
piping however flange adapter locking devices or a welded flange
at the pump should be used to prevent the possibility of pipe
mounted pumps rotating in the piping. Armstrong oers grooved
suction guides with cast-in outlet flanges and Flo-Trex valves with
Armgrip™ fittings to prevent this possibility. (Fig. 2.9)
2.2.10
Do not support the unit by the motor eye bolts (Fig. 2.10) or by any
other part of the motor.
2.2.11
Connecting the pump to a permanent rigid base (Fig.2.11) is not
recommended unless isolated from the piping by flexible connec-
tors and the base isolated from the building structure on an inertia
base. (Fig. 2.11 is generally acceptable when using plastic piping).
2.2.12
The motor and integrated control assembly can be rotated in
90° increments to meet installation spacing requirements.
Where applicable, remove the coupling guard to access the motor
bolts.Remove the motor bolts to rotate the motor and integrated
control assembly by hand.Larger motors may need strapping and
slight lifting to break the contact with the pedestal.Care should
be taken that the controls are not damaged during lifting and
that the flushline, flushline accessories and the coupling guard
removal/seal service window are not compromised following the
turn (Fig. 2.12).vil pumping units without integrated controls can
also be rotated in a similar manner to facilitate access to the the
motor terminal box.
2.2.13
For d1 and d2chassis ivs102 units (150 hp–350 hp), ensure ad-
equate space is available for the access door to swing open.
(Fig. 2.13)
important:
All Design Envelope 4300 pumps contain a tapped hole in the mo-
tor bracket above the discharge flange (see Fig. 2.14) 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.
2.3 pump piping – general
Never connect a pump to piping, unless extra care is taken to
measure and align the piping flanges well. 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 of a
vertical in-line pump, unless the pump is rigidly mounted to a
foundation.
Ensure piping exerts no strain on pump as this could distort
the casing causing breakage or early failure due to pump
misalignment.
All conecting pipe flanges must be square to the pipework and
parallel to the pump flanges.
Suction and discharge pipes may be increased or decreased at
pump nozzle to suit pump capacity and particular conditions of
installation. Use eccentric reducers on suction connection with flat
side uppermost.

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
8
Layout 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 eectively.
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 is typical.
In open systems, test suction line for air leaks before starting; this
becomes essential with long suction line or static lift.
Install, at the pump suction, a straight pipe of a length equivalent
to four or six times its diameter; this becomes essential when han-
dling liquids above 120°f (49°c). Armstrong suction guides may be
used in place of the straight pipe run and in-line strainer.
Install an isolation valve in both suction and discharge lines on
flooded suction application; these valves are used primarily to
isolate the pump for inspection or repair.
Install a non-slam non-return 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 on open systems.
2.4 alignment
Design Envelope 4300 units are accurately aligned at the factory
prior to being shipped and do not need re-aligning when installed.
Alignment on a Design Envelope 4300 unit may be verified by as-
suring an equal and parallel gap between coupling halves on both
sides of the coupling.
operation
2.5 starting pump
Ensure that the pump turns freely by hand, or with some
gentle mechanical help such as a strap or Allen key in
coupling bolt.
Ensure that all protective guarding is securely fixed in position.
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. On Design Envelope 4300 any air trapped in the
casing as the system is filled must be removed by the manual air
vent in the seal flush line. Ensure entrained air is removed from
Design Envelope 4300 pumps, prior to starting, through the air
vent on the seal flush line. Open vent until clear of air.
Design Envelope 4380 units are fitted with seal flush/vent lines
piped to the pump suction area. When these units operate, re-
sidual air is drawn out of the pump towards the suction piping.
Bump or energize the motor momentarily and check that
the rotation corresponds with the directional arrow on the
pump casing (clockwise when viewed from drive end.).
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-ener-
gize the motor.
Do not run the pump against a closed discharge valve for an
extended period of time (a few minutes maximum.)
Should the pump be noisy or vibrate on start-up a common reason
is overstated system head. Check this by calculating the pump
operating head by deducting the suction pressure gauge value
from the discharge gauge reading. Convert the result into the units
of the pump head as stated on the pump nameplate and compare
the values. The system designer or operator should be made
aware of this soon as some adjustment may be required
to the drive settings to make the pump suitable for the system
as installed.
Check rotation arrow prior to operating the unit. The
rotation of all Armstrong Vertical In-Line units is clock-
wise when viewed from the drive end. (Looking from on
top of/behind the motor).
2.6 general care
Vertical In-Line pumps are built to operate without periodic
maintenance, other than motor lubrication on larger units. 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 100°f/40°c).

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
9
warning:
Whenever any service work is to be performed on a
pumping unit, disconnect the power source to the driver,
lock it o and tag with the reason. Any possibility of the
unit starting while being serviced must be eliminated.
If mechanical seal environmental accessories are installed, ensure
water is flowing through the sight flow indicator and that filter car-
tridges are replaced as recommended. (See Armstrong files 43.85
and 43.86 for seal environmental instructions).
2.7 lubrication
Pump
Lubrication is not required. There are no bearings in the pump that
need external lubrication service.
Large Design Envelope 4300 units are installed with a shaft bush-
ing located beneath the impeller that is lubricated from the pump
discharge.
Motor
Follow the lubrication procedures recommended by the motor
manufacturer. Many small and medium sized motors are perma-
nently lubricated and need no added lubrication. Generally if there
are grease fittings evident the motor needs periodic lubrication.
None if not.
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 fitted with a flush line. The seal is flushed from discharge of the
pump casing on Design Envelope 4300 pumps and from the suc-
tion on Design Envelope 4380 pumps.
The Design Envelope 4300 pump is flushed from the pump dis-
charge because the mechanical seal chamber is isolated from the
liquid in the pump by a throttle bushing. Because the seal chamber
is isolated, seal environmental controls such as filters and separa-
tors, when installed in the Design Envelope 4300 flush line are
very eective, as only the seal chamber needs cleansing, and 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.
Mechanical seals may weep slightly at start-up. Allow the pump
to continue operating for several hours and the mechanical seal to
seat properly prior to calling for service personnel.
The following Armstrong files are available for mechanical seal
replacement instructions:
• Series4300: tc Motor Frame – File 43.88
• Series4380: File 43.81
2.8 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.
note:
Particular care must be taken to check the following before the
pump is put into operation:
aPump primed?
b RotationOK?
c LubricationOK?
dPipe work properly supported?
e VoltagesupplyOK?
f OverloadprotectionOK?
gIs the system clean?
hIs the area around the pump clean?
warranty
Does not cover any damages to the equipment resulting from
failure to observe the above precautions. Refer to Armstrong
General Terms and Warranty sheet. Contact your local Armstrong
representative for full information.
fig. 2.1 Hanger supported pipe mounted

installation &
operating instructions
Design Envelope 4300 & 4380
Vertical In-line Pumping Unit
10
fig. 2.2 Pipe mounted supported at ceiling
fig. 2.3 Discharge elbow for minimum footprint
Page 7 of 26
Fig. 2.4 With additional pipe supports
Fig. 2.6 Additional floor support
Fig. 2.8 Seismic region installation
Fig. 2.3 Discharge elbow for minimum footprint
Fig. 2.5 Floor saddle support
Fig. 2.7 With stanchion plates
Seismically Rated Snubbers or
Pads and Concrete Foundation
fig. 2.4 With additional pipe supports
Page 7 of 26
Fig. 2.4 With additional pipe supports
Fig. 2.6 Additional floor support
Fig. 2.8 Seismic region installation
Fig. 2.3 Discharge elbow for minimum footprint
Fig. 2.5 Floor saddle support
Fig. 2.7 With stanchion plates
Seismically Rated Snubbers or
Pads and Concrete Foundation
fig. 2.5 Floor saddle support
Page 7 of 26
Fig. 2.4 With additional pipe supports
Fig. 2.6 Additional floor support
Fig. 2.8 Seismic region installation
Fig. 2.3 Discharge elbow for minimum footprint
Fig. 2.5 Floor saddle support
Fig. 2.7 With stanchion plates
Seismically Rated Snubbers or
Pads and Concrete Foundation
Hangers support the weight
of the filled piping, pumps
and fittings
Hangers support the weight
of the filled piping, pumps
and fittings
Pipe hanger (typ.)
See specification
for size and type
Pipe hanger (typ.)
See specification
for size and type
Hangers support the weight
of the filled piping, pumps
and fittings
Pipe hanger (typ.)
See specification
for size and type
System outlet
System outlet
System outlet
Flo-Trex valve
Flo-Trex valve
Flo-Trex valve
Flo-Trex valve
Pipe support
Flush line
Flush line
Flush line
System inlet
System inlet
System inlet
Split
coupler
Split
coupler
Drain connection
Drain connection
Drain connection
Pet cock
(typ.)
Pet cock
(typ.)
2' or 3'
height above
finished floor
2" or 3"
height above
finished floor
Recommended field
pressure gauge piping
arrangement
Recommended field
pressure gauge piping
arrangement
Recommended field
pressure gauge piping
arrangement
Neoprene
isolation pad
Suction
guide
Suction guide
Split coupler
Hangers support the weight
of the filled piping, pumps
and fittings
Suction guide