Armstrong Design Envelope 4302 User manual

Design Envelope
4302 & 4382
Vertical In-line Pumping
Unit with ivs drive
Installation and
operating instructions
File No: 104.80
Date: january 21, 2019
Supersedes: 104.80
Date: august 08, 2018

contents
1.0 introduction 4
1.1 precautions 4
1.1.1 uncrating 4
1.1.2 handling design envelope
4302 and 4382 units 4
1.2 mechanical installation 4
1.2.1 location 4
1.2.2 storage 4
1.2.3 installation 5
1.2.4 pump piping – general 5
1.2.5 armstrong dualarm hvac pump
flapper valve operating instructions 6
2.0 electrical setup 10
2.1 remove cover 10
2.2 precautions 10
2.2.1 ground leakage current 10
2.2.2 start / stop of pump 10
2.2.3 additional motor protection 11
2.3 electrical installation 11
2.3.1 supply voltage 11
2.3.2 supply fusing 11
2.3.3 grounding and it mains 11
2.3.4 relay connections 12
2.3.5 electrical installation and
control connections 13
2.3.6 control terminals 14
2.4 design envelope pump
controller wiring 16
2.4.1 ethernet and wifi connectivity 16
2.4.2 can bus wiring 16
2.4.3 rs 485 wiring 16
2.4.4 networking options 16
3.0 networking controls 17
3.1 modbus ip & rtu 18
3.2 BACnet ip & ms/tp 21
4.0 operation 22
4.1 start-up checklist 22
4.2 starting pump 22
4.2.1 auto flow balancing 23
4.3 touch screen 24
4.3.1 login 24
4.3.2 logout 24
4.3.3 about 24
4.3.4 general settings 25
4.3.5 manual/auto mode 26
4.3.6 pump control 27
4.3.7 alarms & warnings 30
4.3.8 trend-graph 31
4.3.9 brightness adjustment 31
4.3.10 touch screen calibration 32
4.3.11 data logging 33
4.4 web interface 34
4.4.1 connecting via ethernet 34
4.4.2 connecting via wifi 34
4.4.3 switching frequency 34
4.5 design envelope flow
readout tolerance 35
5.0 control modes 35
5.1 constant flow 35
5.2 constant pressure 35
5.3 linear pressure 35
5.4 quadratic curve control 36
5.5 quadratic curve control with
minimum flow protection 36
5.6 quadratic curve control with
maximum flow protection 36
5.7 quadratic curve control with
minimum & maximum flow protection 36
5.8 parallel sensorless
pump control (pspc) 36
5.8.1 embedded parallel sensorless
pump control for multiple pumps 37
5.9 2*100% capacity split units 38
5.10 duty-standby mode 38
5.11 alternation 38
6.0 maintenance 39
6.1 general care 39
6.2 lubrication 39
6.3 mechanical seal 39
6.3.1 mechanical seal replacement instruc-
tions for 4302 split coupled vertical
in-line pump 39
6.3.2 mechanical seal replacement instruc-
tions for 4382 close coupled vertical
in-line pump 41
7.0 warnings and alarms 42
7.1 alarm summary for interfaces 42
7.2 warning summary for interfaces 43
8.0 fuse and wire recommendation 44
9.0 pump manager 45

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
4
1.0 introduction
This manual contains specific information regarding the safe
installation, operation and maintenance of Armstrong Design
Envelope pumps. Read this manual carefully before installing or
using the product. If clarification is needed on any point please
contact Armstrong quoting the equipment serial number.
1.1 precautions
1.1.1 uncrating
Armstrong dualArm Design Envelope 4302 and 4382 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 pack-
ing list. Any shortages or damage should be reported imme-
diately. 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.
1.1.2 handling design envelope 4302 and
4382 units
Design Envelope 4302 and 4382 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
1.2 mechanical installation
1.2.1 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.
If the ivs controls are supplied with integral disconnect switch-
es, 36ins / 1meter clearance may be required in front of the
controls to meet local electrical codes.
Electric motor driven pumps should not be located in damp or
dusty location without special protection.
1.2.2 storage
Pumps not immediately placed into service, or removed from
service and stored, must be properly prepared to prevent rust-
ing. 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.
design envelope 4382 design envelope 4302

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
5
1.2.3 installation
The most important consideration when installing a Design
Envelope 4302 and 4382 pumping unit is to make sure the
pump is free to float with expansion and contraction of the pip-
ing. Recommended arrangements are:
• Supported from the ceiling by pipe hangers (See fig. 1.7 on
page 8)
• Pipe supported at the ceiling, with the dualArm free-stand-
ing and mounted with an Armstrong Suction Guide & Flo-
Trex valve. (See fig. 1.8 and fig. 1.9 on page 8)
• Piping supported at ceiling with additional floor mounted
supports under Armstrong Suction Guide and Flo-Trex
Valve (See fig. 1.10 on page 8)
• Floor mounted saddle supports (See fig. 1.11 on page 9)
• Where required, additional floor support may be obtained
as shown in fig. 1.12. Note that the pump must not be rig-
idly 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. 1.13 on page 9) Note: if the pump must be con-
nected 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 Design Envelope 4302 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.
1.2.4 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.
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 es-
sential 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 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 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 in-
stallation, 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 con-
ditions and will cause premature failure and could cause seri-
ous and dramatic damage to the pump and surrounding area.
note:
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.

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
6
1.2.5 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 neces-
sary, 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.
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
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).
3 Rotate 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).
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.
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
1 Open 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.
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 verti-
cal position, locking the center pin in the locking arm recess,
secure with set screw (11).

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
7
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
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 lock-
ing 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
note:
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 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
1 Open 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.
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.
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")
fig. 1.2 suction valve fig. 1.3 discharge valve
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).
16
3
1
Normal operation Normal operation

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
8
fig. 1.4 valve illustration (8")
fig. 1.5 suction valve fig. 1.6 discharge valve
fig. 1.7 hanger supported pipe mounted
fig. 1.8 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. 1.9 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
fig. 1.10 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
4
This pump suction is now
closed. (Locked when handle
is elevated and secured).
Normal operation Normal operation
This pump discharge is now
closed. (Locked when handle
is elevated and secured).
3
1
16

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
9
fig. 1.11 floor saddle support
fig. 1.12 additional floor support
GAP
fig. 1.13 not recommended
fig. 1.14 tapped collection well on design
envelope 4302
Design Envelope 4312
seal leaks or condensate
drain hole. Plumb to
drain for area
cleanliness
fig. 1.15 clearance note
1 m (40") clearance in front of
controls may be required in
your locale

installation &
operating instructions
Design Envelope 4302 & 4382
Vertical In-line Pumping Unit
10
2.0 electrical setup
2.1 remove cover
Remove front cover to access mains and grounding connec-
tions, and control terminals. Carefully lift the cover from the
bottom edge to remove. do not pry the cover open from the
side edges.
When replacing the front cover, please ensure proper fastening
by applying a torque of 2Nm.
do
not
pry
do
not
pry
do not
pry
from
sides
2.2 precautions
The standard enclosure rating for Design Envelope
4302 and 4382 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)
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.
All electrical connections should be carried out 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
switching o, wait for at least 15 minutes for the
capacitors to discharge before opening the cover.
caution
High voltage testing (Megging) of the motor/ con-
trols may cause damage to the electronic compo-
nents and therefore should not be carried out.
2.2.1 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:
1 Switching frequency
2 Motor grounded on site or not
The leakage current is of importance to safety during handling
/ operation of the Design Envelope 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
2.2.2 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
Design Envelope pumps.