Armstrong 4200H User manual

Design Envelope
4200H & 4280
End suction horizontal
pumping units with
ivs drive
Installation and
operating instructions
File No: 103.80
Date: january 21, 2019
Supersedes: 103.80
Date: august 08, 2018

contents
1.0 introduction 4
1.1 precautions 4
1.1.1 instructions for safe use 4
1.1.2 ambient temperature 4
1.1.3 enclosure rating 4
1.1.4 noise levels 4
1.1.5 vibration levels 5
1.1.6 storage 5
1.1.7 warranty 5
1.1.8 uncrating 5
1.1.9 handling design envelope 4200H &
4280 pumping units 5
1.2 mechanical installation 6
1.2.1 location 6
1.2.2 installation 6
1.2.3 grouting 7
1.2.4 pump piping – general 7
2.0 electrical setup 8
2.1 remove cover 8
2.2 precautions 8
2.2.1 ground leakage current 8
2.2.2 start / stop of pump 9
2.2.3 additional motor protection 9
2.3 electrical installation 9
2.3.1 supply voltage 9
2.3.2 supply fusing 9
2.3.3 grounding and it mains 9
2.3.4 relay connections 10
2.3.5 electrical and control connections 12
2.3.6 control terminals 13
2.4 design envelope pump
controller wiring 15
2.4.1 ethernet and wifi connectivity 15
2.4.2 can bus wiring 15
2.4.3 rs 485 wiring 15
2.4.4 networking options 15
3.0 networking controls 16
3.1 modbus ip & rtu 17
3.2 BACnet ip & ms/tp 20
4.0 operation 22
4.1 start-up checklist 22
4.2 starting pump 22
4.2.1 auto flow balancing 22
4.3 touch screen 23
4.3.1 login 23
4.3.2 logout 23
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
5.9 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
instructions for 4200h split
coupled vertical in-line pump 39
6.3.2 mechanical seal replacement
instructions for 4280 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 4200h & 4280
End Suction Horizontal Pumping Units
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 instructions for safe use
No installation of this equipment should take place
unless this document has been studied and under-
stood. Handling, transportation and installation of this
equipment 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.
1.1.2 ambient temperature
Install the Design Envelope unit with adequate access
for routine maintenance. A minimum of 2" (50 mm)
clearance is required at the fan inlet to facilitate
airflow. Where several Design Envelope units are installed in
close proximity, care must be taken to ensure that there is no
re-circulation of exhausted warm air.
Under normal operating conditions the pump surface tempera-
ture may reach 68°c/ 155°f (Restricted Zone) to 80°c/176°f
(Unrestricted Zone). 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°f and not
withstanding pump insulation techniques appropriate mea-
sures must be taken to minimize risk for operating personnel.
The ambient temperature for standard motors must be no
greater than 40°c/104°f.
1.1.3 enclosure rating
The standard enclosure rating for Design Envelope
4200H and Design Envelope 4280 integrated
controls is ul Type 12 / ipp55. If the pump is to be
installed in a wet or dusty environment, then a higher enclosure
rating may be required (contact Armstrong).
1.1.4 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
tefc tefc tefc
hp db-a hp db-a hp db-a
140 158 1-2 64 1.5-2 79
180 1.5-2 61 3-5 68 3-5 82
210 3-5 65 7.5-10 73 7. 5-10 85
250 7.5-10 69 15-20 78 15-20 88
280 15-20 74 25-30 82 25-30 89
320 25-30 77 40-50 83 40-50 94
360 40-50 80 60-75 89 60-75 95
400 60-75 84 100 92 100 96
440 100-125 88 125 96 125 98

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
5
1.1.5 vibration levels
Armstrong end-suction horizontal pumps are designed to meet
vibration levels set by Hydraulic Institute Standard hi Pump
Vibration 9.6.4. Standard levels are as detailed below
Factory 5.3 mm/s (0.21 in/s) 200 kW (268 bhp) & above
Factory 4.3 mm/s (0.17 in/s) below 200 kW (268 bhp)
Field 3.3 mm/s (0.13 in/s) below 200 kW (268 bhp)
Overall Vibration Velocity (mm/s) RMS
Overall Vibration Velocity (in/s) RMS
Pump power, bhp
Pump power, kW
Field 4.3 mm/s (0.17 in/s) 200 kW (268 bhp) & above
10
101
0
1
2
3
4
5
6
7
8
9
10
100
100
1000
1000 10000
0
0.1
0.2
0.3
0.4
1.1.6 storage
Pumps not immediately placed into service, or removed from
service and stored, must be properly prepared to prevent
excessive 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 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.
1.1.7 warranty
Armstrong’s warranty period for Design Envelope pumps
is [18] months from date of shipment, or [12] months from
date of installation, whichever comes first. Please refer to File
9.10us / 9.10c for full terms and conditions. To receive an ad-
ditional [6] months of standard coverage, owner may register
the pump unit at
www.armstrongfluidtechnology.com/warrantyregistration
1.1.8 uncrating
Armstrong pumping units are thoroughly inspected before
shipment to assure they meet with your order requirements.
After removing the pump from the packaging, 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 controller, pump or
motor. Never place cable slings around the pump shaft or in-
tegrated controls. The eye bolts or lifting lugs on the motor are
intended for lifting only the motor and not the complete unit.
1.1.9 handling design envelope 4200H &
4280 pumping units
Design Envelope pumping units Series de 4200H end-suction
base mounted & de 4280 end-suction close coupled units bring
the convenience of ‘plug & play’ units, as pre-set controls are
an integral component of the ul std 778 & csa std c22.2 No 108
certified pumping units. These controls, though adding typical
high value from lower installed cost for the installing contrac-
tor and inherent energy savings for the building owner, involve
integrated controls that are not delicate though do need more
care during installation than standard pump and motor compo-
nents and must be handled accordingly.
Spacer bars for lifting straps or chains, may be used to ensure
the straps or chains do not exert pressure the pump and motor
housings and really must be used, with extra care, around the
controls housing.

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
6
fig 1.1 lifting horizontal design envelope pumps
using spacer beams
fig 1.2 lifting horizontal design envelope pumps us-
ing base lifting holes
fig 1.3 lifting close coupled design envelope pumps
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.
1.2 mechanical installation
1.2.1 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 connection. 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 Design Envelope
controls are supplied with integral disconnect switches,
36"/1meter clearance may be required in front of the controls
to meet local electrical codes.
1.2.2 installation
The following text and illustrations are oered as general sug-
gestions for the preparation of a satisfactory foundation.
Foundation should be suciently substantial to absorb any
vibration and permanently support the baseplate at all points.
This is essential in maintaining the alignment of a direct
coupled unit.
Horizontal Design Envelope units are inherently soft start and
operate the majority of the time at lower than synchronous
speed. This means that the huge (About 3-times the weight
of the pumping unit) inertia bases are not required and much
more simple vibration isolation may be used.
If the unit is to be mounted on fabricated steel work or similar
structure, the unit should be set over, or as near as possible to,
the supporting beams or walls and to be so supported that the
baseplate cannot be distorted by any yielding or springing of
the structure or base.
The (4) corner holes should be used as a minimum. All (6)
holes can be used on larger bases. Secure evenly spaced straps
placed under the baseplate is also acceptable for lifting the
entire unit.
Horizontal Design Envelope pumping units are supplied with
rigid split couplings (DE 4200H) or are close-coupled (DE
4280), as such no alignment is necessary in the field.

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
7
Place pumping unit on the foundation and insert metal wedges
on either side of the foundation bolts under base plate. Leave
approximately 0.75" (19mm) space if grouting.
Carefully level the unit by adjusting the wedges until base is
supported in a level position
With the proper gauge, check suction and discharge flanges of
the pump for proper positioning.
When the baseplate is completely level, the foundation bolts
should be tightened evenly and firmly.
1.2.3 grouting
Armstrong’s fabricated steel base plates, as supplied with
4200H Design Envelope pumps, are manufactured to ansi/hi
1.3.5 rigidity standards for free-standing base plates. As such,
no grouting in place is necessary for the base plate to hold shaft
alignment of any Armstrong base mounted pumping unit. End-
suction horizontal base mounted Design Envelope pumping units
are supplied with rigid couplings which need no re-alignment at
installation or following seal service. Thus grouting is not neces-
sary; though the following instructions are for installers who still
wish to also secure the base in place with grout:
• Construct a dam around the foundation with grout forms, as
shown in the illustration.
• Use a good mixture of non-shrinking grout. The grout
should be the consistency of heavy cream.
• Spaces are provided in the base plate to permit pouring of
the cement and stirring. Fill under the base completely, stir-
ring to assure proper distribution of the grout. Check to see
that the grout flows under the base plate evenly.
• When the grout has hardened thoroughly, usually after
48 hours, final tighten the anchor bolts and remove the
grout forms.
1.2.4 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 connecting 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.
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 equiva-
lent to four or six 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 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.
Armstrong Flo-Trex valves may be used in place of isolation
valves and non-return check valves. Flo-Trex valves use plug
& disk design which may also be used for throttling excessive
system flow for constant speed pumps and, if necessary, for
variable speed pumps. Do not throttle variable speed pumps
unless absolutely necessary.
note:
Design Envelope 4200H units are accurately aligned at the factory
prior to being shipped and do not need re-aligning when installed.
Alignment on a Design Envelope 4200H unit may be verified by
assuring an equal and parallel gap between coupling halves on
both sides of the coupling.
•
Install foundation bolts
•
Install grout forms
•
Fill in base with grouting

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
8
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
To avoid the ivs unit getting overheated, the ambient
temperature is not to exceed 133°f (45°c) average
daily temperature. Operating in higher ambient tem-
peratures 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 inverter 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/inverter
may cause damage to the electronic components 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:
1Switching frequency
2Motor grounded on site or not
The leakage current is of importance to safety during handling/
operation of the pump if (by mistake) the on-board inverter has
not been grounded.
Since the leakage current is >3.5ma(approx 4-20ma), rein-
forced 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

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
9
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
connected). This is the preferred method of starting and
stopping 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-tempera-
ture 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 ivs nameplate.
Please ensure that the unit is suitable for the electrical supply
on which it is to be used. The mains supply for 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 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.
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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.
Do not connect frequency converters with rfi-filters
to mains supplies with a voltage between phase and
ground of more than 440 v for 400 v converters and
760 v for 690 v converters. For 400 v it mains and delta earth
(grounded leg), mains voltage may exceed 440 v between phase
and earth. For 690 v it mains and delta earth (grounded leg),
mains voltage may exceed 760 v between phase and earth.
fig. 2.1 Terminals for mains and grounding
3 phase
power input
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
Page 10 of 26
Figure 3. Mains and Grounding Connections for A5 Units
(200-240V - 5HP and Below, 380-480V / 525-600V - 10HP
and Below)
4.6 GROUNDING AND IT MAINS
The ground connection cable cross section must be at
least 10 mm 2or 2 rated mains wires terminated sepa-
rately 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.
NB!
Check the mains voltage corresponds to the mains volt-
age of the frequency conv erter name plate.
IT Mains
Do not connect frequency converters with RFI-lters to
mains supplies with a voltage between phase and
earth of more than 440 V for 400 V converters and 760 V for
690 V converters. For 400 V IT mains and delta earth
(grounded leg), mains voltage may exceed 440 V between
phase and earth. For 690 V IT mains and delta earth
(grounded leg), mains voltage may exceed 760 V between
phase and earth.
Figure 2. Terminals for Mains and Grounding
Figure 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)
Figure 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
91
L1 92
L2 93
L3
95
95

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
10
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)
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 connec-
tions for c1 and c2 units (200 -240V –
25 to 60hp, 380-480V – 50 to 125hp,
525-600V – 60 to 125hp)
fig. 2.3c Mains and grounding connections for d1 and d2
units (380-480v – 150 to 350hp, 525-600v – 150to
350hp)
95
2.3.4 relay connections
The relays on the 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
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:
95
95
95
91
L1
92
L2
93
L3

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
11
01 02 03
04 05 06
AUX RELAY
fig. 2.5 Relay connection: terminals for a5, b1 and b2 units
fig. 2.6 Relay connection terminals for c1 and c2 units
fig. 2.7 Relay connection terminals for c1 and c2 units

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
12
2.3.5 electrical and control connections
fig. 2.8 Diagram showing all electrical connections
*Note: Terminal 37 is not available on Design Envelope pumps
3-Phase Power
input(1-ph
power: No 92
(l2)connection)
Reserved for control module

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
13
2.3.6 control terminals
With reference to figure 10:
fig. 2.9 Control Connections
For connection to external devices such as start / stop switch-
es, dierential pressure sensors, or temperature sensors etc.,
refer to the following wiring instructions to the terminals and
webserver configuration screens.
terminal
no.
type /
description factory setting
webserver
configuration
ref
1, 2, 3 Relay 1Alarm G
4, 5, 6 Relay 2Run Status G
18 Digital Input 1Start / Stop A
19 Digital Input 2Start / Stop B
27 Digital Output
1
Alarm, Flow
Threshold, Head
Threshold,
Run Status
E
29 Digital
Output 2
Alarm, Flow
Threshold, Head
Threshold,
Run Status
F
42 Analog Output Speed
53 Analog Input 1 Speed Control,
Pressure Sensor C
54 Analog Input 2Speed Control,
Pressure Sensor D
*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 9) 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 ac-
cess when making connections.
Page 14 of 26
4.8.1 ACCESS TO TERMINALS
Remove front-cover to access control terminals. For D1 and
D2 chassis IVS units access swings open. (see Fig. 2.13) .
When replacing the front cover, please ensure proper fasten-
ing by applying a torque of 2 Nm.
4.8.2 CONTROL TERMINALS
With reference to gure 10:
1. 10 way plug for digital I/O
2. 3 way plug for RS485 Bus
3. 6 way plug for analogue I/O
4. USB Connection
Control terminal functions and factory settings are as follows:
*Note that Analogue inputs AI53 and AI54 can be either Volt-
age (0-10V) or Current (4-20mA) input and by default both
inputs are set to Voltage.
Switches S201 and S202 (see gure 9) are used to congure
the analogue inputs as follows:
S201 (AI53) OFF = Voltage, ON = Current
S202 (AI54) OFF = Voltage, ON = Current
Inserting Cables into Control Terminals
i) Strip 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 re-
moved for improved access when making
connections.
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 0V
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 Output Output Frequency
(4-20mA - 0-100Hz)
53 Analogue Input Reference (0-10V)*
54 Analogue Input Feedback (0-10V)*
Figure 10. Control Connections
Page 14 of 26
4.8.1 ACCESS TO TERMINALS
Remove front-cover to access control terminals. For D1 and
D2 chassis IVS units access swings open. (see Fig. 2.13) .
When replacing the front cover, please ensure proper fasten-
ing by applying a torque of 2 Nm.
4.8.2 CONTROL TERMINALS
With reference to gure 10:
1. 10 way plug for digital I/O
2. 3 way plug for RS485 Bus
3. 6 way plug for analogue I/O
4. USB Connection
Control terminal functions and factory settings are as follows:
*Note that Analogue inputs AI53 and AI54 can be either Volt-
age (0-10V) or Current (4-20mA) input and by default both
inputs are set to Voltage.
Switches S201 and S202 (see gure 9) are used to congure
the analogue inputs as follows:
S201 (AI53) OFF = Voltage, ON = Current
S202 (AI54) OFF = Voltage, ON = Current
Inserting Cables into Control Terminals
i) Strip 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 re-
moved for improved access when making
connections.
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 0V
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 Output Output Frequency
(4-20mA - 0-100Hz)
53 Analogue Input Reference (0-10V)*
54 Analogue Input Feedback (0-10V)*
Figure 10. Control Connections
110-way plug for
digital i/0
23-way plug for
rs485 bus
36-way plug for
analogue i/0

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
14
webserver configuration
Select Pump in the left side-menu
For Digital Inputs (A, B) that have been wired:
1 Select On/O, then
2 Select Update
For Analog Inputs (C, D) that have been wired:
1 Select Speed or Pressure, for the control type
2 Select Current or Voltage,
3 Enter values in the text box (as applicable),
4 Select Update
For Digital Functions (E, F) that have been wired:
1 Select Enabled, then
2 Select one of Alarm, Flow Threshold, Head Threshold,
or Run Status
3 Enter the threshold value in the text box (as applicable),
4 Select Update
For Digital Inputs (G) that have been wired:
1 Select Enabled, then
2 Select Alarm or Run Status,
3 Select Update

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
15
2.4.2 can bus wiring
Connections, Low, High, and Ground as per fig. 2.10. If the depc requires
a can bus connection, ensure that the terminating resistor switch is set
to Enabled, (towards the en label for the bas ports). If multiple pumps
are connected in parallel for can bus (supplied by others) they should
be daisy chained together. Ensure that only the first and last terminating
resistor switches are set to Enabled.
2.4.3 rs 485 wiring
For Modbus rtu or BACNet ms/tp connection to building automation
system, connect rs485 cable to this port per fig. 2.10. If the depc is
connected to the bas, ensure that the terminating resistor switch is set to
Enabled (towards the en label for the bas ports).
If multiple pumps are connected in parallel to the bas, the bas wiring
(supplied by others) should be daisy chained together. Ensure that only
the first and last terminating resistor switches are set to Enabled. See
example below in fig 2.10.1
fig. 2.10.1
pump controller 1
A = + Positive
B = - Negative
G = Ground
pump controller 2
A = + Positive
B = - Negative
G = Ground
pump controller 3
A = + Positive
B = - Negative
G = Ground
pump controller 4
A = + Positive
B = - Negative
G = Ground
b
ag
b
ag
bag
ba
g
2.4.4 networking options
fig. 2.11
2.4 design envelope pump
controller wiring
fig. 2.10 Controller Board
fig. 2.10a Controller Board
2.4.1 ethernet and wifi connectivity
For BACNet tcp/ip connection to building automa-
tion system, connect connect rj-45 cable to this port
per fig. 2.10
rs-485
6.1
6.2
bms
bms
CAN bus
Modbus
A = + Positive
B = - Negative
G = Ground

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
16
3.0 networking controls
For connection to the building automation system (bas), the
pump needs to be properly configured to the network. En-
sure the rs485 cable is connected to the controller board
(fig.2.10). Or if connecting to the bas via router, ensure that
the rj-45 cable is connected to the controller board (fig. 2.10
).
The pump controls can be configured from the touchscreen or
the webserver.
For BACNet ms/tp or tcp/ip: Enter the BACNet address, baud
rate, and unique device instance number (as applicable)
For Modbus rtu or tcp/ip: Enter the Modbus address, baud
rate, and parity stop bits (as applicable)

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
17
3.1 modbus ip & rtu
function code
start
address
modbus
register description # of
registers
change
during
operation
data
type unit notesread write
0×01 0×03 0×05 0×06
Status
x100 101 Actual speed 1n/a uint16 1 rpm The current speed of the vfd in
rpm.
x101 102 Actual speed 1n/a uint16 0.1 % The current speed of the vfd in %
of the nominal motor speed.
x102 103 Motor input
power 2n/a uint32 0.01 Units as configured on pump
control module.
x104 105 Motor input
voltage 1n/a uint16 0.1 V Voltage delivered by the vsd to
the motor.
x105 106 Motor input
current 2n/a uint32 0.01 A Current delivered by the vsd to
the motor.
x107 108 Sensorless
head 2n/a uint32 0.01 Units as configured on pump
control module.
x109 110 Sensorless flow 2n/a uint32 0.01 Units as configured on pump
control module.
x111 112 Total flow 2n/a uint32 0.01 Used for parallel sensorless mode
x113 114 Total power 2n/a uint32 0.01 Used for parallel sensorless mode
x115 116 Number of
running pumps 1n/a uint16 —Used for parallel sensorless mode
x116 117 Max sensorless
flow 2n/a uint32 0.01 Units as configured on pump
control module.
x118 119 Max sensorless
head 2n/a uint32 0.01 Units as configured on pump
control module.
x120 121 btu/h 2n/a uint32 —Not implemented
i/o
x200 201 Digital in 1n/a uint16 —Digital input 1is bit 0and input 2
is bit 1.
x201 202 Analog in 12n/a uint32 0.01 V,
0.01 mA
Units as configured on Pump
Control Module
x203 204 Analog in 22n/a uint32 0.01 V,
0.01 mA
Units as configured on Pump
Control Module
x205 206 Analog Out 11n/a uint16 0.01 mA
x206 207 Digital Out 1n/a uint16 —Digital output 1is bit 0and output
2is bit 1.
x207 208 Relays 1n/a uint16 —Relay 1is bit 0and relay 2is bit 1.
Units
x250 251 Flow units 1n/a uint16 —1= l/s; 2= m3/h;
3= g/m
x251 252 Pressure units 1n/a uint16 —1= bar; 2= kPa;
3= psi; 4= ft; 5 = m
x252 253 Power units 1n/a uint16 —1= kW; 2= hp
x253 254 Speed units 1n/a uint16 —1= rpm; 2= %
x254 255 Temperature
units 1n/a uint16 —1= °c; 2 = °f

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
18
function code
start
address
modbus
register description # of
registers
change
during
operation
data
type unit notesread write
0×01 0×03 0×05 0×06
Counters
x275 276 Total pump
running hours 2n/a uint32 1h
x x 277 278 Trip pump
running hours 2n/a uint32 1h Writing 0to this register resets
the counter.
x279 280 Total controller
running hours 2n/a uint32 1 h
x281 282
Present
controller
running hours
2n/a uint32 1 hThe running hours since the
controller was powered on.
x283 284
Total pump
running kWh
counter
2n/a uint32 1kWh
x x 285 286
Trip pump
running kWh
counter
2n/a uint32 1kWh Writing 0to this register rests the
counter.
x287 288 Total btu
counter 2n/a uint32 —Not implemented
x x 289 290 Trip btu
counter 2n/a uint32 —Not implemented
Control Settings
x300 301 Control mode 1Yes uint16 —
1= Parallel
2 = i/o
3= Remote
4= Constant flow
5= Constant pressure
6= Linear pressure
7= Quadratic pressure
8= Quad pressure max.
9= Quad pressure min.
10 = Quadratic
pressure max/min
x x 301 302 hoa state 1Yes uint16 —
0 = O
1= Hand
2= Auto
x x 302 303 Active
parameters 1Yes uint16 —
1= standard
2= mode 1(heating mode)
3 = mode 2(cooling mode)
x x 303 304 Minimum
speed limit 1Yes uint16 0.1 Units as configured on pump
control module.
x x 304 305 Maximum
speed limit 1Yes uint16 0.1 Units as configured on pump
control module.
x x 305 306 Hand mode
speed 1Yes uint16 0.1 Units as configured on pump
control module.
x x 306 307 bms set speed 1Yes uint16 0.1 Units as configured on pump
control module.
Alarms and Warnings
x400 401 Alarms 2n/a uint32 —Refer to alarms table for bit posi-
tions
x402 403 Warnings 2n/a uint32 —Refer to alarms table for bit posi-
tions
xx404 405 Acknowledge
Warnings 2Yes uint32 —32-bit field corresponding to the
warning field

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
19
function code
start
address
modbus
register description # of
registers
change
during
operation
data
type unit notesread write
0×01 0×03 0×05 0×06
Parameters
x(x)500 501
Standard
mode – zero
flow head
2Yes uint32 0.01
Value for standard active mode.
Units as configured on Pump
Control Module. (Key required to
write.)
x(x)502 503
Standard
mode – design
head
2Yes uint32 0.01
Value for standard active mode.
Units as configured on Pump
Control Module. (Key required to
write.)
x(x)504 505
Standard
mode – design
flow
2Yes uint32 0.01
Value for standard active mode.
Units as configured on Pump
Control Module. (Key required to
write.)
x(x)506 507
Standard
mode –
minimum flow
2Yes uint32 0.01
Value for standard active mode.
Units as configured on Pump
Control Module. (Key required to
write.)
x(x)508 509 Mode 1– zero
flow head 2Yes uint32 0.01
Value for active mode 1. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)510 511 Mode 1–
design head 2Yes uint32 0.01
Value for active mode 1. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)512 513 Mode 1–
design flow 2Yes uint32 0.01
Value for active mode 1. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)514 515 Mode 1–
minimum flow 2Yes uint32 0.01
Value for active mode 1. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)516 517 Mode 2– zero
flow head 2Yes uint32 0.01
Value for active mode 2. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)518 519 Mode 2–
design head 2Yes uint32 0.01
Value for active mode 2. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)520 521 Mode 2–
design flow 2Yes uint32 0.01
Value for active mode 2. Units
as configured on Pump Control
Module. (Key required to write.)
x(x)522 523 Mode 2–
minimum flow 2Yes uint32 0.01
Value for active mode 2. Units
as configured on Pump Control
Module. (Key required to write.)
Information
x900 901 Pump name /
tag name 8n/a ascii —The pump name as a series of
ascii characters.
x908 909 Serial number 7n/a ascii —Serial no. Of the pump
represented by ascii characters
x915 916 Firmware
version 1n/a uint16 00.00
Divide the number by 100 to get
the major. Minor version of the
depc.
x916 917 Hardware
version 1n/a uint16 —The pump control module
hardware version.
x917 918 Modbus
version 1n/a uint16 —Version of the Armstrong
Modbus version

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
20
3.2 BACnet ip & ms/tp
object id object name read/write comments
Status
av:100 Actual speed Read in rpm
av:101 Actual speed Read in %
av:102 Motor input power Read Unit as configured in pump control module
av:103 Motor input voltage Read in volts
av:104 Motor input current Read in amps
av:105 Sensorless head Read Unit as configured in pump control module
av:106 Sensorless flow Read Unit as configured in pump control module
av:107 Total flow Read Used for parallel sensorless mode
av:108 Total power Read Used for parallel sensorless mode
av:109 No. of running pumps Read Used for parallel sensorless mode
av:110 Max sensorless flow Read Unit as configured in pump control module
av:111 Max sensorless head Read Unit as configured in pump control module
av:112 btu/h Read Not implemented
Counters
av:275 Total pump running hours Read
av:276 Trip pump running hours Read/Write Writing 0 to this register resets the counter.
av:277 Total controller running hours Read
av:278 Present controller running hours Read The running hours since the controller was powered on.
av:279 Total pump running kwh counter Read
av:280 Trip pump running kwh counter Read/Write Writing 0 to this register resets the counter.
av:281 Total btu counter Read Not implemented
av:282 Trip btu counter Read Not implemented
Control Settings
av:300 Control Mode Read
1 = Parallel; 2= i/o; 3= Remote; 4= Constant flow; 5= Constant pressure; 6=
Linear pressure; 7= Quadratic pressure; 8= Quadratic pressure with maximum
flow; 9= Quadratic pressure with minimum flow; 10 = Quadratic pressure with
minimum and maximum flow
av:301 hoa State Read/Write 0 = O; 1 = Hand mode; 2 = Auto
av:302 Active Parameters Read/Write 1= standard; 2 = mode 1 (heating mode); 3 = mode 2 (cooling mode)
av:303 Minimum Speed Limit Read in rpm
av:304 Maximum Speed Limit Read in rpm
av:305 Hand Mode Speed Read/Write in rpm
av:306 bms Set Speed Read/Write in rpm
Alarms and Warnings
av:400 Alarms Read Refer to alarms table for bit positions
av:401 Warnings Read Refer to warnings table for bit positions
av:402 Acknowledge Warnings Read/Write 32-bit field corresponding to the warning field