Armstrong 4280 Series User manual

Design Envelope
4200H & 4280
End suction horizontal
pumping units with
permanent magnet 1-10
hp motor
Installation and
operating instructions
File No: 103.82
Date: september 21 , 2018
Supersedes: 103.82
Date: june 18 , 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 vibration levels 4
1.1.5 storage 5
1.1.6 warranty 5
1.1.7 uncrating 5
1.1.8 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 system installation 7
1.2.4 suction guide 7
1.2.5 leveling 7
1.2.6 installation for seismic mounts 8
1.2.7 vertical shaft installation 8
1.2.8 pump piping – general 8
2.0 electrical setup 9
2.1 precautions 9
2.1.1 ground leakage current 9
2.1.2 start / stop of pump 10
2.1.3 additional motor protection 10
2.1.4 motor thermal protection and
derating 10
2.2 electrical specification 11
2.3 electrical installation 12
2.3.1 power wiring 12
2.3.2 tools you will need 12
2.3.3 the main cover disassembly 13
2.3.4 control terminal wiring 14
2.3.5 analog / digital inputs 14
2.3.6 digital output 17
2.3.7 relay output 17
2.3.8 supply voltage 17
2.3.9 supply fusing 17
2.4 design envelope pump
controller wiring 18
2.4.1 battery 18
2.4.2 ethernet and wifi connectivity 18
2.4.3 can bus wiring 18
2.4.4 rs 485 wiring 18
2.4.5 networking options 18
3.0 networking controls 19
3.1 modbus ip & rtu 20
3.2 BACnet ip & ms/tp 23
4.0 operation 25
4.1 start-up checklist 25
4.2 starting pump 25
4.3 touch screen 26
4.3.1 login 26
4.3.2 logout 26
4.3.3 about 26
4.3.4 general settings 27
4.3.5 manual/auto mode 28
4.3.6 pump control 29
4.3.7 alarms & warnings 33
4.3.8 trend-graph 33
4.4 web interface 34
4.5 design envelope flow readout
tolerance 34
4.6 noise levels 34
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 35
5.5 quadratic curve control with
minimum flow protection 35
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 parallel sensorless pump control
for multiple single pumps 36
5.9 2*100% capacity split units 37
5.10 duty-standby mode 37
5.11 alternation 37
6.0 maintenance 38
6.1 general care 38
6.2 lubrication 38
6.3 mechanical seal 38
6.3.1 mechanical seal replacement instruc-
tions for rigid split- coupled pumping
units (series 4300, 4200h & 4322) 39
6.3.2 mechanical seal replacement instruc-
tions for close-coupled pumping units
(series 4380, 4280 & 4372) 40
6.4 system cleanliness 42
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
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
1.0 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 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

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
5
1.1.5 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
material and covering the flanges is acceptable. When
returning to service be sure to remove the drying agent from
the pump.
1.1.6 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
1.1.7 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
integrated controls.
1.1.8 handling design envelope 4200h &
4280 pumping units
To handle Design Envelope 4200h & 4280 units when re-
ceived on site, secure the pallet after uncovering the unit, then
hook straps as detailed below and in fig 1.1.1 to lift the pump-
ing unit. Connect one set of lifting straps to the lifting rings on
each side of the integrated motor. A second lifting strap should
be secured around the suction nozzle.
fig 1.1.1
Extra care is required to ensure the integrated controls do not
get damaged during lifting and installation. 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.
The Design Envelope 4200h and 4280 pumping units 1-10hp
are equipped with integral vibration isolators. Note that the
springs are temporarily secured to the pumping unit by 4sets
of packaging sleeves. These must be removed once the pumps
are positioned in place.
fig 1.1.2

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
6
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,
3 6"/ 1 meter clearance may be required in front of the controls
to meet local electrical codes.
1.2.2 installation
The Design Envelope 4200h and 4280 pumping units 1-10hp
are equipped with integral vibration isolators and do not re-
quire inertia bases or baseplates for horizontal (shaft orienta-
tion), base-mounted installations. The vibration isolators are
pre-sized for the pumping unit and will reduce the transmission
of noise and vibration from the pump and piping system to the
building structure.
fig 1.2.1
The springs use anti-friction neoprene cup mounts and prevent
lateral movement of the pump. If accurate positioning of the
spring cups is required, gently use a tool, such as the end of a
flat-head screwdriver (or crowbar) to tap the cups into place.
fig 1.2.2

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
7
1.2.3 system installation
Refer to fig 1.2.3 for the recommended installation of Design
Envelope 4200h and 4280 pumping units 1-10hp pumps.
fig 1.2.3 a
If the installation uses horizontal inlet piping, a flex connector
should still be installed before the suction port of the pump.
fig 1.2.3 b
1.2.4 suction guide
It is recommended that suction guides be mounted directly to
the pump’s suction port. This acts as a counter weight to the
weight of the motor to ensure the center of gravity is main-
tained between the front and back springs isolators. A support
pipe under the suction guide should not be used – this may
transmit forces from the pump or piping system to the ground
structure, resulting in unwanted noise or vibration.
fig 1.2 .4
Flex connectors should be installed directly before the suction
guide (or suction port), and directly after the pump’s discharge
port. This will eectively isolate the transmission of noise or
vibration between the piping system and the pump.
1.2.5 leveling
It is recommended that the Design Envelope 4200h and 4280
pumping units 1-10hp pumps be leveled for general pump op-
eration. Note that the rigid pedestal on 4200h and close-cou-
pled design on 4280s allows these pumps to operate properly
by up to 0.25" (6mm) of non-level mounting.
To level the pumps equipped with the standard integral spring
isolators, start by removing the shrouds from the front and
back of the pump fig 1.2.5. Lift the shrouds up to detach from
pump, then remove the two shroud halves apart.
fig 1.2.5
system
inlet
system
outlet
housekeeping
pad
suction
guide
drain
connection
flex
connector
flex connector
vibration
springs
flo-trex
valve
system
inlet
system outlet
housekeeping
pad
flex
connector
flex connector
springs
isolators
flo-trex valve
suction
guide

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
8
Turn the cast knob clockwise to increase
the free & operating height, or counter-
clockwise to decrease the height. The free
& operating heights by pump model are
listed in the below table
de 4200h/4280,
spring type
free & operating
height
Standard Spring
Isolators
3.75" (95 mm)
Seismic Mount 5.00" (127 mm)
The shrouds can then be re-assembled to the pump by
fastening the 2halves together around the pump foot and
motor foot. Push the shroud assembly down and ensure the
shroud pins click into the locator holes in the castings.
1.2.6 installation for seismic mounts
Pumps equipped with the Seismic Mount option have seismic
mounts factory pre-installed to the feet and must be bolted
to the ground structure. Anchor rods may be either cast-in
place or post-installed. Ensure the anchoring and mounts are
installed along the long side of the pump (as shown in fig 1.2.6)
fig 1.2.6
¼" × 1" (25mm)
locking cap screw
free & operating
height
down stop
½" × 4" (100mm)
adjustment bolt
all-directional
neoprene snubber
upward rebound
plate is adjustable
to control clearance
interchangeable
steel spring
neoprene
acoustical cup
Take 2full counter-clockwise turns on each leveling bolt and
continue even adjustment of all mounts until all springs are
loaded and mountings are back to Free and Operating Height.
Take no more than two additional counter-clockwise turns on
any leveling bolt to level equipment.
Tighten cap screws to secure equipment.
Adjust plates so there is V" (3mm) clearance between top
of plate and underside of all-directional neoprene cushion. Turn
rebound plates clockwise to lower, or counter-clockwise
to raise.
1.2.7 vertical shaft installation
Design Envelope 4200h and 4280 pumping units 1-10hp may
be safely installed in a vertical shaft orientation as shown in fig
1.2.7. The motor fan must be in an upright position; with the
suction port facing down. When installed vertically, the integral
springs and shrouds should be removed from the base of pump.
fig 1.2.7
1.2.8 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.
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.
Turn
cast knob
cw=
ccw=
non-skid neoprene
acoustical cup

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
9
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
equivalent 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.
2.0 electrical setup
2.1 precautions
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.
2.1.1 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 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
10
2.1.2 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.
2.1.3 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
2.1.4 motor thermal protection and
derating
The Design Envelope motors are thermally protected in case
limits are exceeded (140°c), another protection is provided
thought the drive.
a derating for ambient temperature
The ambient temperature (tamax) is the maximum tempera-
ture allowed.
If the motor is operated at temperatures above 104°f (40°c),
a derating of the continuous output current is necessary.
b derating for air pressure
Below 1000 m altitude no derating is necessary. Above 1000
m the ambient temperature (ta) or max. rated output cur-
rent (in) must be de-rated in accordance with the following
diagram.
See the below diagram for derating of output current versus
altitude at ta = Max. 104°f (40°c)
c derating for running at low speed
When a centrifugal pump or a fan is controlled by a 4200h
& 4280 Motor, it is not necessary to reduce the output at
low speed because the load characteristic of the centrifugal
pumps/ fans, automatically ensures the necessary reduction.
The 4200h & 4280 Permanent Magnet motors running con-
stant load torque applications continuously at low speed must
be de-rated (see diagram) or an independent fan must be used.
in the Permanent Magnet motors all control terminals are sup-
plied from or in connection with extra low voltage (pelv).
The components that make up the electrical isolation, as de-
scribed below, also comply with the requirements concerning
higher isolation and the relevant test as described in en 50178.
The galvanic isolation can be shown in three locations (see
drawing below),namely:
0
20
40
60
80
100
0500 1000 1500 2000 2500 3000 3500
ratedtorque [%]
altitude[m]
deratingforair pressure
0
20
40
60
80
100
120
20 30 40 50 60 70
outputcurrent
tambient[°c]
deratingforambienttemperature
0
20
40
60
80
100
010002000300
04
000
ratedtorque [%]
ratedspeed[rpm]
deratingforrunningatlowspeed

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
11
1 Power supply (smps) including signal isolation of VDCbus,
indicating the intermediate voltage.
2 Gate drive that runs the IGBTs (opto couplers)
3 DCbus Voltage transducer (opto couplers)
4 Current transducers (Hall Eect-Based Current Sensor).
31 4 2
M
d earth leakage current
Earth 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 earth through capacitors (Cy).
The size of the leakage current to the ground depends on the
following factors, in order of priority:
1 Switching pwm frequency
2 Motor grounded on site or not
The leakage current is of importance to safety during
handling/operation of the drive if (by mistake) the drive has
not been earthed.
e over voltage protection
The voltage in the intermediate circuit is increased when the
motor acts as a generator. This occurs in two cases:
1 The load generates energy.
2 During deceleration (ramp-down) if the moment of inertia
is high, the load is low and the ramp-down time is too short
for the energy to be dissipated as a loss in the motor fre-
quency converter, the motor and the installation.
The drive turns o to protect the igbt transistors and the
intermediate circuit capacitors when a certain voltage level is
reached on DCbus.
f mains supply interference/harmonics
A motor integral drive takes up a non-sinusoidal current from
mains. A non-sinusoidal current can be transformed by means
of a Fourier analysis and split up into sine wave currents with
dierent frequencies, i.e. dierent harmonic currents in with
50 Hz as the basic frequency.
Some of the harmonic currents might disturb communication
equipment connected to the same transformer or cause reso-
nance in connection with power-factor correction batteries.
To ensure low, harmonic currents, for the residential and com-
mercial environments, an optional harmonic filter is necessary.
2.2 electrical specification
Main supply (l1 l2 l3)
Supply frequency 48 - 62Hz
Supply voltage 1 × 200-230v± 10% ,
3 × 200-230v± 10% ,
3 × 380-480v± 10% ,
3 × 575-600v± 10%
Max. imbalance of
supply voltage
± 2% of rated supply
Switching on
supply voltage
Once every 2minutes
Output ratings
Output Current 100% Drive Rated Power continuously
Overload Capacity 150% for 60 secs
Digital inputs
Programmable
digital inputs
2
Voltage level 0-24Vdc (user selectable npn or pnp)
Analog input
Programmable
analog voltage input
1
Voltage level 0:10Vdc
Input resistance Rin 10KΩ
Resolution 12bit
Programmable
analog current inputs
1
Current range 0:20mA
Input resistance Rin 500Ω
Relay Output
Programmable relay
output
2(n.o. n.c. com)
Max terminal load 250Vac 2A 500VA

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
12
Externals
Enclosure ip55
Vibration test ec 60068-2-6
Max relatively
humidity
95% (iec 60068-2-3)
Operating ambient
temperature
0:40°c
Storage ambient Temperature - 25°c:60°c
Min. ambient
temperature at full
operation
0°c
Altitude 0 - 3000m, de-rate 1% per 100m
above 1000m
Compliance with Standards
en 61800-3:2004 Adjustable speed electrical power
drive systems. emc requirements
iec 61800-5-1 Adjustable speed electrical drive sys-
tems - part 5-1: safety requirements
- electrical, thermal and energy
en 60204-1 Safety of machinery - electrical emc
equipment of machines-part 1: gen-
eral rules
2.3 electrical installation
2.3.1 power wiring
fig 2.3.1 Upper right corner of the motor. Use Access port #1
for power wiring and ground.
pin1 l1 l1 power supply
pin2 l2 l2 power supply
pin3 l3 l3 power supply
2.3.2 tools you will need
Ground
l3
Access1
Access2l2
l1
2.5 &
3 mm

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
13
1 2 3
4 5 6
2.3.3 the main cover disassembly
caution
When you remove the front cover, pay attention to
the wiring connection of the control board, unplug the
connection and remove completely the cover.
a
b
2.5 mm
warning
Before removing the system must be disconnected
from the mains supply. After switching o, wait for at
least 4minutes for the capacitors to discharge before
opening the cover.
a
b
3mm
power
from
mcc
ethernet
cable
router

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
14
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 Design Envelope Pumps.
The three phase mains must be isolated before
performing maintenance of the pump.
2.3.4 control terminal wiring
fig 2.3.2 Motor Control Board
2.3.5 analog / digital inputs
a wiring
Digital
Input
Wiring
Analog
Input
Wiring

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
15
personnel requirements
1 Armstrong Tier 3training or equivalent
2 Ability to terminate simple control wiring
3 Ability to configure Armstrong controls
4 All work will be done on low voltage, however, when remov-
ing the controller cover high voltage may be exposed. An
electrician license is required in some areas
i wiring digital inputs
1 Connect one port of the contact to digin1 or digin2.
2 Connect the other port to +24vext
ii wiring analog inputs
a for speed control through analog input
1 Connect signal source to anin1 Or anin2
2 Connect the other port to gnd
b for speed control through differential
pressure sensor
1 Connect signal source to anin1 Or anin2
2 Connect the power port to +24vext or external +24v
b setting the analog / digital inputs from
web interface
i setting the digital inputs from the web
interface
Login to the web interface (Check Web Interface in section 4.4)
From Setting Pump
Under Digital Input 1/ Digital Input 2, Select On/O and hit
Update
ii setting the analog inputs from the web
interface
Login to the web interface (Check Web Interface in section 4.4)
Go to Setting Pump
a setting speed control through current
signal 4-20ma
Under Control Mode, select InputsAnalog in 1, or
Analog in 2 speedCurrent click Update
b setting speed control through voltage
signal 0-10v
Under Control Mode, select InputsAnalog in 1, or
Analog in 2 speed Voltage click Update

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
16
c setting speed control through differential
pressure (dp) sensor 4-20ma
1 Under Control Mode, select InputsAnalog in 1 or
Analog in 2Pressure Current
2 Set the DP sensor setting:
• Min(mA): 4
• Max(mA): 20
• Min Pressure: the minimum limit in the DP sensor
• Max Pressure: the max limit in the DP sensor
• Zone 1 Pressure set point: the desire set pressure
point
3 Click Update
d setting speed control through differential
pressure (dp) sensor 0-10v
1 Under Control Mode, select Inputs Analog in 1 or
Analog in 2 Pressure Voltage
2 Set the DP sensor setting:
• Min(V): 0
• Max(V): 10
• Min Pressure: the minimum limit in the DP sensor
• Max Pressure: the max limit in the DP sensor
• Zone 1Pressure set point: the desire set pressure
point
3 Click Update

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
17
c setting the differential pressure (dp) sensor through lcd
Set the current\ voltage DP sensor setting:
• Set Sensor Signal Intervals
• Set Sensor Pressure range
• Set desire zone pressure
• Click Confirm
2.3.6 digital output
If either of the digital outputs are to be used for voltage dif-
ferential, a 500 ohm resistor (supplied by others) must be con-
nected between the respective digital output and the 24VEXT
terminal. Refer to fig 2.3.6
fig 2.3.6
2.3.7 relay output
J5 & J8 for Relay output
j8
n.o. 2 Relay n.o.
n.c.2 Relay n.c.
com2 Relay 2A 250Vac
j5
n.o. 1 Relay n.o.
n.c. 1 Relay n.c.
com 1 Relay 2A 250Vac
2.3.8 supply voltage
The supply voltage details can be found on the 4200h &
4280 nameplate. 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 × 200-230v± 10% ,
3 × 200-230v± 10% ,
3 × 380-480v± 10% ,
3 × 575-600v± 10%
Frequency - 50/60Hz
2.3.9 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. Please refer
to section 8.0 (Fuse and wire recommendation).
Short circuit protection
The inverter must be protected against short-circuit to avoid
electrical or fire hazard. The frequency converter provides full
short circuit protection in case of a short-circuit on the motor
output.
Vdig_out2
Vdig_out1
V
V
500 Ohm
500 Ohm

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
18
2.4 design envelope pump
controller wiring
fig 2.4 Controller Board
fig 2. 4a
Modbus
CAN bus
rs-485
bms
bms
2.4.1 battery
The battery is used to power the real-time clock whenever the pump is
disconnected from mains power. It is recommended the battery be changed
periodically every 2to 3years.
2.4.2 ethernet and wifi connectivity
For BACNet tcp/ip connection to building automation system, connect connect
rj-45 cable to this port per fig. 2.4
2.4.3 can bus wiring
Connections, Low, High, and Ground as per fig. 2.4
2.4.4 rs 485 wiring
For Modbus rtu or BACNet ms/tp connection to building automation system,
connect rs485 cable to this port per fig. 2.4
2.4.5 networking options
A = + Positive
B = - Negative
G = Ground

installation &
operating instructions
Design Envelope 4200h & 4280
End Suction Horizontal Pumping Units
19
3.0 networking controls
For connection to the building automation system (bas), the
pump needs to be properly configured to the network. Ensure
the rs485 cable is connected to the controller board (fig.2.4).
Or if connecting to the bas via router, ensure that the rj-45
cable is connected to the controller board (fig. 2.4 ).
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
20
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 Con-
trol Module
x203 204 Analog in 22n/a uint32 0.01 V,
0.01 mA
Units as configured on Pump Con-
trol 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