Armstrong Design Envelope 4312 User manual

Design Envelope
4312 & 4392
Vertical In-line
Twin Pumping Unit
with ivs drive
Installation and
operating instructions
File No: 105.80iec
Date: janaury 21, 2019
Supersedes: 105.80iec
Date: august 08, 2018

contents
1.0 introduction 4
1.1 precautions 4
1.1.1 uncrating 4
1.1.2 handling design envelope
4312 and 4392 units 4
1.2 mechanical installation 4
1.2.1 location 4
1.2.2 storage 4
1.2.3 installation 4
1.2.4 pump piping – general 5
2.0 electrical setup 7
2.1 remove cover 7
2.2 precautions 7
2.2.1 ground leakage current 7
2.2.2 start / stop of pump 8
2.2.3 additional motor protection 8
2.3 electrical installation 8
2.3.1 supply voltage 8
2.3.2 supply fusing 8
2.3.3 grounding and it mains 8
2.3.4 relay connections 9
2.3.5 electrical installation and
control connections 10
2.3.6 control terminals 11
2.4 design envelope pump
controller wiring 13
2.4.1 ethernet and wifi connectivity 13
2.4.2 can bus wiring 13
2.4.3 rs 485 wiring 13
2.4.4 networking options 13
3.0 networking controls 14
3.1 modbus ip & rtu 15
3.2 BACnet ip & ms/tp 18
4.0 operation 19
4.1 start-up checklist 19
4.2 starting pump 19
4.2.1 auto flow balancing 20
4.3 touch screen 21
4.3.1 login 21
4.3.2 logout 21
4.3.3 about 21
4.3.4 general settings 22
4.3.5 manual/auto mode 23
4.3.6 pump control 24
4.3.7 alarms & warnings 27
4.3.8 trend-graph 28
4.3.9 brightness adjustment 28
4.3.10 touch screen calibration 29
4.3.11 data logging 30
4.4 web interface 31
4.4.1 connecting via ethernet 31
4.4.2 connecting via wifi 31
4.4.3 switching frequency 31
4.5 design envelope flow readout
tolerance 32
5.0 control modes 32
5.1 constant flow 32
5.2 constant pressure 32
5.3 linear pressure 32
5.4 quadratic curve control 33
5.5 quadratic curve control with
minimum flow protection 33
5.6 quadratic curve control with
maximum flow protection 33
5.7 quadratic curve control with
minimum & maximum flow protection 33
5.8 parallel sensorless
pump control (pspc) 33
5.8.1 embedded parallel sensorless
pump control for multiple pumps 34
5.9 2*100% capacity split units 35
5.10 duty-standby mode 35
5.11 alternation 35
6.0 maintenance 35
6.1 general care 35
6.2 lubrication 36
6.3 mechanical seal 36
6.3.1 mechanical seal replacement
instructions for 4312 split coupled
vertical in-line pump 36
6.3.2 mechanical seal replacement
instructions for 4392 close coupled
vertical in-line pump 37
7.0 warnings and alarms 39
7.1 alarm summary for interfaces 39
7.2 warning summary for interfaces 40
8.0 fuse and wire recommendation 41
9.0 pump manager 42

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
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 Design Envelope 4312 and 4392 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 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 4312 and
4392 units
Design Envelope 4312 and 4392 twin pumps are handled in
a similar manner to the normal twin pumping 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 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, mainte-
nance, service and inspection of parts.
If the ivs controls are supplied with integral disconnect
switches, 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.
Rustproofing or packing the casing with moisture absorb-
ing material and covering the flanges is acceptable. When
returning to service be sure to remove the drying agent from
the pump.
1.2.3 installation
The most important consideration when installing a Design
Envelope 4312 and 4392 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. 1.1 on
page 5)
• Pipe supported at the ceiling, with the twin free-standing
and mounted with an Armstrong Suction Guide & Flo-Trex
valve. (See figs. 1.2 & 1.3 on page 6)
• Piping supported at ceiling with additional floor mounted
supports under Armstrong Suction Guide and Flo-Trex
Valve (See fig. 1.4 on page 6)
•
Floor mounted saddle supports (See fig. 1.5 on page 6)
• Where required, additional floor support may be obtained
as shown in fig. 1.6. 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.
design envelope 4392 design envelope 4312

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
5
• Do not rigidly connect the pump to a permanent base
(See fig. 1.7 on page 6) Note: if the pump must be
connected to a permanent base, the pump must be iso-
lated 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 4312 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 dis-
tort the casing and cause pump misalignment.
Suction and discharge pipes may be increased at pump noz-
zle to suit pump capacity and particular conditions of installa-
tion. 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 for-
eign materials into the pump. V" (3mm) diameter perfora-
tions 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 equiva-
lent 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 iso-
late 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.
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 con-
cern 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 serious and dramatic damage to the pump and sur-
rounding area.
note:
The pumping unit is accurately aligned at the factory prior to
being shipped.
Alignment on the Design Envelope 4312 twin may be verified
by assuring an equal gap between coupling halves on both
sides of the coupling.
fig. 1.1 hanger supported pipe mounted

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
6
fig. 1.2 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. 1.3 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
fig. 1.4 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. 1.5 floor saddle support
fig. 1.6 additional floor support
GAP
fig. 1.7 not recommended

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
7
1 m (40") clearance in front of
controls may be required in
your locale
fig. 1.8 tapped collection well on design
envelope 4312
Design Envelope
4312
seal leaks or condensate
dr
ain hole. Plumb to
dr
ain for area
cleanlines
s
fig. 1.9 clearance note
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 han-
dling / operation of the Design Envelope pump if (by mis-
take) the on-board inverter has not been grounded.

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
8
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 stop-
ping Design Envelope pumps.
The three phase mains must be isolated before performing
maintenance of the pump.
2.2.3 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-temperature 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
2.3 electrical installation
2.3.1 supply voltage
The supply voltage details can be found on the ivs102 name-
plate. Please ensure that the unit is suitable for the electrical
supply on which it is to be used. The mains supply for Design
Envelope pumps is as follows:
1 × 200-240v ± 10%
3 × 200-240v ± 10%
3 × 380-480v ± 10%
3 × 525-600v ± 10%
Supply frequency - 50/60Hz
2.3.2 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.
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 ivs Operating Instructions to
protect 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.
2.3.3 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er-
ently. 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.
Do not connect frequency converters with rfi-fil-
ters 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. 2.1 terminals for mains and grounding
3 phase
power input
91
(l1)
(l2)
(l3)
pe
92
93
95
2. Place plug connector 91, 92, 93 from the accessory bag onto the terminals labelled MAINS at the bottom of the frequency converter.
3. Connect mains wires to the mains plug connector.
The earth connection cable cross section must be at least 10 mm2or 2 rated mains wires terminated separately according to EN 50178.
The mains connection is fitted to the main switch if this is included.
NB!
Check that mains voltage corresponds to the mains voltage of the frequency converter name plate.
IT Mains
Do not connect 400 V frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than
440 V.
For IT mains and delta earth (grounded leg), mains voltage may exceed 440 V between phase and earth.
Illustration : Terminals for mains and earthing.
5 How to Install VLT
®
AQUA Drive Design Guide
122 MG.20.N5.02 - VLT®is a registered Danfoss trademark
5
1 phase
power input

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
9
fig. 2.2 Mains and grounding connections for a5 units
(200-240V - 1.5hp 1ph/5hp and below 3ph,
380-480V/525-600V - 10hp and below)
95
fig. 2.3a Mains and grounding connections for b1 and
b2 units (200-240V - 2 to 7.5hp 1ph / 7.5 to
20hp 3ph, 380-480V - 15 to 40hp, 525-
600V – 15 to 50hp)
fig. 2.3b Mains and grounding con-
nections for c1 and c2 units
(200-240V – 25 to 60hp,
380-480V – 50 to 125hp,
525-600V – 60 to 125hp)
2.3.4 relay connections
The relays on the ivs are configured as follows:
Relay 1 – alarm
• Terminal 01:Common
• Terminal 02:Normal Open 240v ac
• Terminal 03: Normal Closed 240v ac
Relay 2 – run status
• Terminal 04: Common
• Terminal 05: Normal Open 400v ac
• Terminal 06: Normal Closed 240v ac
fig. 2.4 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. 2.5 relay connection: terminals for a5, b1
and b2 units
fig. 2.6 relay connection terminals for c1
and c2 units
95
95
91
L1
92
L2
93
L3

installation &
operating instructions
Design Envelope 4312 and 4392 vertical in-line
twin pumping unit with ivs drive
10
2.3.5 electrical installation and control connections
fig. 2.7 diagram showing all electrical connections
*Note: Terminal 37 is not available on Design Envelope pumps
Reserved for control module
3-Phase Power
input(1-ph
power: No 92
(l2)connection)