Armstrong 4000 User manual

IPS controller
4000
Integrated pumping
system for variable
primary application
Installation and
operating instructions
File No: 90.97
Date: december 15, 2015
Supersedes: new
Date: new

contents
1.0 ips controllers 4000 4
1.1 Installation instructions 4
1.2 Enviromental limits 4
1.3 Field devices installation instructions 4
1.4 Building automation system (bas)
connection 4
2.0 ips 4000 function displays 5
3.0 Operation displays 6
4.0 Setup displays 13
5.0 ips 4000 control system service lifecycle 23

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
4
Armstrong Integrated pumping system controllers, ips control-
lers 4000, are completely factory-assembled, tested, and
shipped to the job site as integral units ready to receive incom-
ing power supply. These instructions describe the procedures
to be followed during installation, commissioning and operation
to ensure optimum performance and reliability. When contact-
ing the factory for assistance, please provide the unit serial
number and other pertinent data, such as ips model no.
1.0 ips controllers 4000
1.1 installation instructions
Incoming supply – stand-alone ips controllers (no rack): The
incoming power supply should be brought in through the bot-
tom of the panel adjacent to the main terminals. Note that this
is the only electrical connection required at the panel.
The power supply voltage is 100-240 vac / 50-60 Hz as stan-
dard. Please refer to the wiring diagram supplied with the unit
for instructions on connecting power to the ips controller.
Incoming supply – ips system on rack: The incoming power
supply to the ips controller is achieved through a transformer
in the main enclosure of the whole ips system rack. No power
connection is required.
note: All electrical wiring should be performed by a qualified
electrician in accordance with the latest edition of the National
Electrical Code, local codes and regulations.
1.2 enviromental limits
Operation temperature range: 0°c to 50°c (32°f to 122°f)
(must not be exposed to direct sunlight)
Operation humidity range: (10% - 85%) non-condensing
Ambient air temperature for storage: -20°c to 70°c
(-4°f to 158°f)
1.3 field devices installation
instructions
Prior to using the display to configure the ips controller, make
sure all the field installed devices such as dp sensors, flow
sensors, dp switches are properly installed and wired to the ips
controller as per wiring diagrams provided.
1.4 building automation system
(bas) connection
When the ips controller is provided with a serial port to com-
municate serially to the bas, the possible communication
protocols are Modbus, LonWorks or BACnet. Refer to wiring
diagrams supplied with the unit for wiring instructions. ips
controller can also communicate to the bas through a hard
wired option. Please refer to the ips controller generic terminal
block diagram for the dierent parameters and data points
communicated to the bas. For more information please contact
your local Armstrong representative or Armstrong factory
service department.

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
5
2.0 ips 4000 function displays
The ips 4001 / 4002 / 4003 controllers displays are divided
in two set of displays: Operation and Setup. The Operation dis-
plays are used by the operators to monitor and control the ips.
The Setup screens are used to set, view, save, and restore the
system specific settings (i.e. number of pumps, chillers/boilers,
sensor range, etc.).
operation displays:
• Main menu
• System overview
• Zone overview
• Pump overview
• Sensorless overview
• Pump control
• Bypass valve overview
• Auto bypass reset
• Login
• Alarm overview
• Diagnostics
setup displays:
The setup displays are divided in three levels each with dier-
ent level of access. Level 0setup displays are for viewing only
and no adjustments can be made. Level 1setup displays can be
used for changing the system setup and restoring the system
factory defaults. Level 2setup displays can be used for chang-
ing the system setup, and saving and restoring the system
factory defaults. To access Level 1 and 2an operator need to
enter the proper password (please contact Armstrong factory
service department).
The list of setup/default displays for every level is as follow:
• System setup
• Zone setup
• Zone 1to 12 setup
• Sensorless setup
• Pump setup
• Speed setup
• Staging setup
• pid setup
• bas setup
• Clock setup
• Bypass valve setup
• System valves setup
• vfd readout setup
• Chiller/boiler 1to 6setup
• Flow setup

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
6
3.0 operation displays
3.1.0 main menu
Description
This is the screen the operator sees when powering up the
unit. It indicates status of the system’s most important vari-
ables, and also provides a means for the user to navigation to
all system screens
Data
ips status Indicates if the ips is on or o
Alarm If there is an alarm in the system, a red bell
appears at the top left corner
Buttons
rem – loc Slider button that allows changing the ips
mode to remote or local.
Local will turn on the ips immediately. Remote
causes the ips to follow the bas signal
(hard wired or serial communication) to turn
on or o
zone overview Changes the screen to Zone Overview. Not
available if the vfd type is ivs sensorless
bypass valve
overview
Changes the current screen to Bypass valve
Overview
system
overview
Changes the current screen to System
Overview
sensorless
overview
Changes the current screen to Sensorless
Overview. Only available if the sensorless
control is enabled
setup screen Navigates to the setup menu level zero screen
pump overview Navigates to the Pump Overview screen
alarm screen Shows the alarm screen. If there is an active
alarm, this button turns red
3.1.1 system overview
Description
Shows a detailed view of the system. The screen adapts to the
configuration of the system by showing the number of pumps
and chillers/boilers, the system flow , bypass valve, zone PVs
or head and flow. Press the xon the top right corner to go back
to the previous screen
Data
Chiller/boiler
1to 6status
The icons show the device status:
grey – stopped
green – running
Pump 1to 6status The pump icons shows the pump status:
grey – stopped
green – running
red - alarm
Pump 1to 6mode Shows each pump mode: Hand, O or Auto
Pump 1to 6duty Shows each pump duty: Duty1, Duty2, Duty3,
Duty4, Duty5, Duty6or Stand-by
Pump 1to 6speed Shows each pump speed in percentage
active zone Indicates which zone is assigned as Active.
Not visible if the vfd type is ivs sensorless
deviation Indicates the active zone deviation. Not vis-
ible if the vfd type is ivs sensorless
setpoint Indicates the active zone setpoint in the
chosen units. Not visible if the vfd type is ivs
sensorless and also system valves control is
disabled
max open vlv Indicates the opening of the driving sys-
tem valve. Not visible if the vfd type is ivs
sensorless and also system valves control is
disabled
flow Indicates both sensor and sensorless flow
values in the system based on the selection
head Indicates the total head in the system. Only
visible if the vfd type is ivs sensorless

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
7
delta Indicates how far from the control curve the
pump(s) are operating. The ips regulates the
pump speed to achieve an error of zero
ips status Indicates whether the ips is on or off
alarm A red bell indicates an Alarm in the system
bypass valve Indicates valve position in percentage (100%
means fully open)
minimum flow Indicates the rated minimum chiller/boiler
flow. Updates dynamically based on number
of chillers/boilers enabled
maximum flow Indicates the rated maximum chiller/boiler
flow. Updates dynamically based on number
of chillers/boilers enabled
Buttons
Pump 1to 6icon Touching a pump icon brings up the
corresponding pump control screen
3.1.2 zone overview
Description
Shows an overview of the system zones. If there are more than
3zones, use the grey arrows to scroll. This screen is not avail-
able if the vfd type is ivs sensorless
Data
actual Indicates the present value of the zone
sensor in the selected units
setpoint Indicates the setpoint of the zone in the
selected units
deviation Indicates the zone deviation in the
selected units
status Indicates whether the zone is enabled
or disabled
active zone Indicates which zone is assigned as active
active zone
deviation
Indicates the active zone deviation in the
selected units
Buttons
main menu Navigates to the main menu
system
overview
Changes the current screen to System
Overview
pump overview Changes the current screen to Pump Over-
view
alarms Shows the alarm screen. If there is an active
alarm, this button turns red
bypass overview Changes the current screen to Bypass
Overview
3.1.3 pump overview
Description
Allows monitoring pump information. If there are more than 3
pumps, scroll using the arrows on the top corners
Data
Pump 1to 6mode Shows each pump mode: Hand, O or Auto
Pump 1to 6
status 1
Shows each pump duty: Duty1, Duty2, Duty3,
Duty4, Duty5, Duty6or Stand-by
Pump 1to 6
status 2
Shows if the pump is running or stopped
Pump 1to 6
speed %
Shows each pump speed in percentage
Pump 1to 6
speed rpm
Shows each pump speed in rpm
Run hrs Shows the total pump run time in hours
auto bypass on If the pumps are in auto bypass, the auto by-
pass on label appears on the top left corner.
Touching this label brings up the auto bypass
reset screen

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
8
Buttons
Pump 1to 6Touching a pump button brings up the
corresponding pump control screen. If the
corresponding pump is in alarm, this button
changes to red color
main menu Navigates to the main menu
system overview Changes the current screen to System
Overview
sensorless
overview
Changes the current screen to Sensorless
Overview. Only available if the vfd type is ivs
sensorless
zone overview Navigates to the Zone Overview screen. Not
available if the vfd type is ivs sensorless.
alarms Shows the alarm screen. If there is an active
alarm, this button turns red
bypass overview Changes the current screen to Bypass
Overview
Scroll arrows If there are more than 3pumps in the system,
use the grey arrow buttons to scroll
3.1.4 sensorless overview
Description
This screen is only available when the vfd type is ivs sensor-
less, it complements the Pump Overview screen. If there are
more than 3 pumps, scroll using the arrows on the top corners
Data
Pump 1to 6mode Shows each pump mode: Hand, O or Auto
Pump 1to 6
status 1
Shows each pump duty: Duty1, Duty2, Duty3,
Duty4, Duty5, Duty6or Stand-by
Pump 1to 6
status 2
Shows if the pump is running or stopped
flow Indicates the current flow of that pump in the
selected units
head Indicates the current head of that pump in
the selected units
total flow Indicates the system flow in the selected
units
total head Indicates the system head in the selected
units
Buttons
Pump 1to 6Touching a pump button brings up the
corresponding pump control screen. If the
corresponding pump is in alarm, this button
changes to red color
main menu Navigates to the main menu
system overview Changes the current screen to System
Overview
pump overview Changes the current screen to Pump
Overview
alarms Shows the Alarm Screen. If there is an active
alarm, this button turns red
bypass overview Changes the current screen to Bypass
Overview
Scroll arrows If there are more than 3pumps in the system,
use the grey arrow buttons to scroll
3.1.5 pump 1 to 6 control
Description
This screen allows control of each pump and shows more
detailed information. Press the xon the top right corner to go
back to the previous screen
Data
mode Shows pump mode: Hand, O or Auto
status 1 Shows pump duty: Duty1, Duty2, Duty3,
Duty4, Duty5, Duty6or Stand-by
status 2 Shows if the pump is running or stopped
pump alm Indicates if there is a pump alarm
drv fault Indicates if the vfd is reporting a fault

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
9
run hrs Indicates the pump total run time in hours.
Touching the run hrs label opens a dialog
window to confirm resetting the total run
hours
lead pump switch Indicates the remaining time in days or hours
to switch the Duty1(Lead) pump
speed (%) Shows pump speed in percentage
speed (rpm) Shows pump speed in rpm
current (a) Shows the vfd current
volts (vac) Shows the vfd ac voltage
power (kw) Shows the vfd power in kWs
speed bars Show the pump speed reference and actual
speed in a graphical manner
auto bypass on If the pump is in auto bypass, the auto
bypass on label appears on the bottom of
the screen. Touching this label brings up the
auto bypass reset screen
Alarm If there is a pump alarm, a red bell appears at
the top right corner
Buttons
lead Assigns the pump as Duty1or Lead
hand Changes the pump mode to hand. If the ips is
on, the pump will start immediately and run
at the hand speed (see below)
off Changes the pump mode to o. The pump
will stop immediately and it will be excluded
from the duty rotation
auto Changes the pump mode to auto. The pump
will be assigned a duty status and it will run
according to the ips control algorithm
hand speed If the pump is placed in hand, it will run at
the hand speed entered
3.1.6 bypass valve overview
Description
This screen allows monitoring of the Bypass Valve Overview
feature
Data
position (%) Indicates valve position in percentage (100%
means fully open)
actual flow pv Displays system flow. Obtained from flow
meter or from sensorless readout depending
on the selection
minimum flow Indicates rated minimum chiller/boiler flow.
Updates dynamically based on number of
chillers/boilers enabled
maximum flow Indicates rated maximum chiller/boiler flow.
Updates dynamically based on number of
chillers/boilers enabled
Buttons
mode select Allows user to select the operation mode
manual or auto
hand position If manual mode is selected, the user can
enter the desired valve position
main menu Navigates to the main menu
system
overview
Changes the current screen to System
Overview
pump overview Changes the current screen to Pump
Overview
alarms Shows the alarm screen. If there is an
active alarm, this button turns red
zone overview Changes the current screen to Zone Overview
main menu Navigates to the main menu

installation &
operating instructions
ips 4000 controller - Integrated pumping
system for variable primary applications
10
3.1.7 auto bypass reset
Description
This screen allows the operator to reset the pump auto bypass
condition. Press the x on the top right corner to go back to the
previous screen
Buttons
yes Resets the auto bypass. If the conditions that caused
the auto bypass don’t exist anymore, the pumps will
resume normal operation
no Closes the auto bypass reset screen and returns to the
previous screen
3.1.8 login screen
Description
This screen allows the operator to login to the desired level by
providing the appropiate password
Data
password Shows the encoded password. Touching
it brings up a numeric keypad to enter the
password
Buttons
login If the password entered is valid, touching this
button will change the screen to the setup
menu of the corresponding level
logout Changes the screen back to the main menu
3.1.9 alarm screens
Description
This screen shows the current alarms in the system. Press the
xon the top right corner to go back to the previous screen
Data
Select Select the alarm in order to be acknowledged
and reset
Description Shows the description of the alarm. The possible
alarms are shown below in section 1.2.1
State Provides information about two alarm conditions:
1 Triggered or Not Triggered (Triggered
means that the condition that generates
the alarm is still present, the alarm can be
acknowledged but not reset)
2 Acknowledged or Not Acknowledged
Buttons
reset Resets the alarms.
In order to clear from the list see Reset button
below
diagnostic Brings up the plc diagnostics screen
history Brings up the alarm history screen
Check/
Uncheck
Selects/unselect the alarms. Only selected
alarms can be acknowledged and cleared from
the list
filter Not used
ack Acknowledges the selected alarms
Clear Clears the selected alarms that are not
triggered
Save Not used