Armstrong Design Envelope 4300 User manual

Design Envelope
4300 & 4380
Vertical In-line pumping
unit with ivs drive
Installation and
operating instructions
File No: 101.82
Date: january 21, 2019
Supersedes: 101.82
Date: august 08, 2018

contents
1.0 introduction 4
1.1 precautions 4
1.1.1 instructions for safe use 4
1.1.2 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 4300
& 4380 units 5
1.2 mechanical installation 6
1.2.1 location 6
1.2.2 installation 6
1.2.3 pump piping – general 7
1.2.4 alignment 8
2.0 electrical setup 10
2.1 remove cover 10
2.2 precautions 11
2.2.1 ground leakage current 11
2.2.2 start/stop of pump 11
2.2.3 additional motor protection 11
2.3 electrical installation 11
2.3.1 supply voltage 11
2.3.2 supply fusing 11
2.3.3 grounding and it mains 12
2.3.4 relay connections 13
2.3.5 electrical and control connections 14
2.3.6 control terminals 15
2.4 design envelope pump controller
wiring 17
2.4.1 ethernet and wifi connectivity 17
2.4.2 can bus wiring 17
2.4.3 rs 485 wiring 17
2.4.4 networking options 17
3.0 networking controls 18
3.1 modbus ip & rtu 19
3.2 BACnet ip & ms/tp 22
4.0 operation 24
4.1 start-up checklist 24
4.2 starting pump 24
4.2.1 auto flow balancing 24
4.3 touch screen 25
4.3.1 login 25
4.3.2 logout 25
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 32
4.3.8 trend-graph 33
4.3.9 brightness adjustment 33
4.3.10 touch screen calibration 34
4.3.11 data logging 35
4.4 web interface 36
4.4.1 connecting via ethernet 36
4.4.2 connecting via wifi 36
4.4.3 switching frequency 36
4.5 design envelope flow readout
tolerance 37
5.0 control modes 37
5.1 constant flow 37
5.2 constant pressure 37
5.3 linear pressure 37
5.4 quadratic curve control 38
5.5 quadratic curve control with
minimum flow protection 38
5.6 quadratic curve control with
maximum flow protection 38
5.7 quadratic curve control with
minimum & maximum flow protection 38
5.8 parallel sensorless pump control
(pspc) 38
5.9 2*100% capacity split units 40
5.10 duty-standby mode 40
5.11 alternation 40
6.0 maintenance 41
6.1 general care 41
6.2 lubrication 41
6.3 mechanical seal 41
6.3.1 mechanical seal replacement instruc-
tions for 4300 split coupled vertical
in-line pump 41
6.3.2 mechanical seal replacement instruc-
tions for 4380 close coupled vertical
in-line pump 43
7.0 warnings and alarms 45
7.1 alarm summary for interfaces 45
7.2 warning summary for interfaces 46
8.0 fuse and wire recommendation 47
9.0 pump manager 48

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
4
1.0 introduction
This manual contains specific information regarding the safe
installation, operation and maintenance of Armstrong Design
Envelope pumps. Read this manual carefully before installing or
using the product. If clarification is needed on any point please
contact Armstrong quoting the equipment serial number.
1.1 precautions
1.1.1 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 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
4300 and Design Envelope 4380 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
odp tefc odp tefc odp tefc
hp db-a hp db-a hp db-a hp db-a hp db-a hp db-a
140 0.75 - 1 59 0.75 - 1 58 1 - 3 64 1 - 2 64 1.5 - 3 70 1.5 - 2 79
180 1.5 - 2 61 1.5 - 2 61 3 - 5 66 3 - 5 68 5 - 7.5 74 3 - 5 82
210 3 - 5 66 3 - 5 65 7.5 - 10 70 7.5 - 10 73 10 - 15 76 7.5 - 10 85
250 7.5 - 10 70 7.5 - 10 69 15 - 20 74 15 - 20 78 20 - 25 78 15 - 20 88
280 15 - 20 75 15 - 20 74 25 - 30 74 25 - 30 82 30 - 40 80 25 - 30 89
320 25 - 30 77 25 - 30 77 40 - 50 78 40 - 50 83 50 - 60 83 40 - 50 94
360 40 - 50 80 40 - 50 80 60 - 75 80 60 - 75 89 75 - 100 88 60 - 75 95
400 60 - 75 82 60 - 75 84 100 - 125 83 100 92 125 - 150 92 100 96
440 100 - 125 85 100 - 125 88 150 - 200 87 125 - 150 96 200 - 250 95 125 - 150 98
440 100 - 125 85 100 - 125 88 150 - 200 87 125 - 150 96 200 - 250 95 125 - 150 98

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
5
1.1.5 vibration levels
Armstrong Vertical In-Line pumps are designed to meet vibra-
tion levels set by Hydraulic Institute Standard hi Pump Vibra-
tion 9.6.4. Standard levels are as detailed below:
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 Vertical In-Line pumps are thoroughly inspected
before shipment to assure they meet with your order require-
ments. 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 controls, 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 4300 & 4380 units
To handle Design Envelope 4300 and 4380 units from shipment,
secure the pallet following uncovering the unit, then placestraps
behind the integrated controls (around the motor feet) and
carefully lift the pumping unit to stand the pump vertically
upright. Lift only suciently to remove the pallet, then lower
onto a flat surface. The pump and motor unit will free-stand on
the casing ribs.Extra care is required to ensure the integrated
controls do not get damaged during lifting and installation.
For Design Envelope 4300 units, remove the coupling guard
and insert lifting straps through the pump/motor pedestal on
either side of the coupling. For Design Envelope 4380 units,
remove the motor eye-bolt and install a swivel hoist ring tied to
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

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
6
a lifting strap. Place secondary lifting straps around the motor
feet (and/or spacers). As the lifting device is engaged (Using a
spacer bar if necessary) and the straps tighten ensure no part
of the strapping is touching any part of the control or motor
fan cover. Lift the pumping unit carefully from the pallet in this
manner and allow the unit to stand upright on a flat surface and
re-position the straps, if necessary, to ensure safe and damage-
free transportation into the pipe installation.
4300 4380
Remove coupling guard and
place lifting straps on each side
of coupling, use spacer bar if nec-
essary to protect the integrated
controls and motor fan cover.
Remove the motor eye-bolt and
install a swivel hoist ring tied to a
lifting strap. Place secondary lift-
ing straps securely around motor
feet (and/or spacers).
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 prema-
ture 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 con-
nection. This is the point of zero pressure change and is neces-
sary 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 ivs 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
When installing vertical in-line pumps, an important consid-
eration to accrue full added-value from the pump design is to
ensure that the pump is pipe-mounted and free to ‘float’ with
any movement, expansion and contraction of the piping. Should
any vertical in-line pump use supports to the structure it is
imperative that no pipe strain is imposed on the pump flanges.
Tell-tale pieces of equipment such as springs or ‘wae’ style
neoprene isolation pads that distort with pressure to indicate
added piping weight, should be used under pump supports
should the pump not be truly pipe mounted.
Design Envelope 4300 and Design Envelope 4380 cannot be
mounted with shafts in the horizontal position.
Various installation arrangements are detailed on Pages 8–10
a
Vertical In-Line pumps may be installed directly in the system
piping with no additional support. Pipe hangers are simply sized
for the additional weight of the pumping unit. Many pumps are
installed in this manner and can be mounted at sucient height
to take zero floor space. (fig. 1.1)
b
Piping in many mechanical rooms is hung close to the ceiling
and larger pumps are mounted near ground level for ease of
maintenance. fig. 1.2 illustrates such an arrangement with the
piping supported at the ceiling and the vil unit installed with an
Armstrong Suction Guide and Flo-Trex valve. Many very large
vil pumps are installed in this manner.
c
Should additional space saving be required the discharge spool
piece may be replaced by a long-radius elbow.
d
Fig 1.4 illustrates a similar arrangement to fig. 1.2 with ad-
ditional floor mounted pipe-stools isolated from the structure
by ‘wae’ style neoprene isolation pads under the Armstrong
Suction Guide and Flo-Trex valve.
e
Floor mounted saddle supports (fig. 1.5) are typical for
condenser water pumps where cooling tower base is at the
mechanical room elevation.

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
7
f
Where required, additional floor support may be used as shown
in fig. 1.6. Note that the pump should not be rigidly attached
to the column. Leave a small gap between pump and column or
install a wae isolation pad under the pump. It is critical that
piping be installed in such a manner that the pump does not
become a pipe support.
g
fig. 1.7 illustrates stanchion plates at the pump inlet and
outlet ports that may be supplied for installation convenience.
Isolation pads must be used under the legs and monitored as
pipe hangers are adjusted to ensure the pump flanges are not
supporting the piping. Bolting to the floor or housekeeping pad
is not recommended. If the stanchions are bolted down the
bolts must be isolated from the stanchion or an inertia base
and flexible pipe connectors used.
h
fig. 1.8 illustrates installations with stanchion plates for seis-
mically active regions. Seismically rated isolation pads or snub-
bers with bolts isolated from the stanchion plates are installed
to restrain the pump during a seismic event. Pipe hangers carry
the weight of the equipment as seismic components are de-
signed only to restrain the equipment during a seismic event.
i
Many Vertical In-Line pumps are piped successfully into
grooved piping systems. In-line pumps are supported well
by grooved piping however flange adapter locking devices
or a welded flange at the pump should be used to prevent
the possibility of pipe mounted pumps rotating in the piping.
Armstrong oers grooved suction guides with cast-in outlet
flanges and Flo-Trex valves with Armgrip™ fittings to prevent
this possibility. (fig. 1.9)
j
Do not support the unit by the motor eye bolts (fig. 1.10) or by
any other part of the motor.
k
Connecting the pump to a permanent rigid base (fig. 1.11) is
not recommended unless isolated from the piping by flexible
connectors and the base isolated from the building structure on
an inertia base. (fig. 1.11 is generally acceptable when using
plastic piping).
l
The motor and integrated control assembly can be rotated
in 90° increments to meet installation spacing requirements.
Where applicable, remove the coupling guard to access the
motor bolts.Remove the motor bolts to rotate the motor and
integrated control assembly by hand.Larger motors may
need strapping and slight lifting to break the contact with the
pedestal.Care should be taken that the controls are not dam-
aged during lifting and that the flushline, accessories and the
coupling guard removal/seal service window are not compro-
mised following the turn (fig. 1.12).vil pumping units without
integrated controls can also be rotated in a similar manner to
facilitate access to the the motor terminal box.
m
For d1 and d2chassis ivs units (150 hp–350 hp), ensure ad-
equate space is available for the access door to swing open.
(fig. 1.13)
important:
All Design Envelope 4300 pumps contain a tapped hole in the
motor bracket above the discharge flange (see Fig. fig. 1.14)
for draining the well. Pipe this drain hole to a floor drain to
avoid overflow of the cavity caused by collecting chilled water
condensate or from seal failure.
1.2.3 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 pipe work
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
equivalent to four or six times its diameter; this becomes es-

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
8
sential 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 exces-
sive back pressure and to prevent water running back through
the pump in case of driver failure on open systems.
1.2.4 alignment
Design Envelope 4300 units are accurately aligned at
the factory prior to being shipped and do not need
re-aligning when installed.
Alignment on a Design Envelope 4300 unit may be verified by
assuring an equal and parallel gap between coupling halves on
both sides of the coupling.
fig. 1.1 Hanger supported pipe mounted
fig. 1.2 Pipe mounted supported at ceiling
System inlet System outlet
Recommended field
pressure gauge piping
arrangement Flo-Trex valve
Split
coupler
Flush line
Drain connection
Suction guide
Hangers support the weight
of the filled piping, pumps
and fittings
Pipe hanger (typ.)
see specification
for size and type
Pet cock
(typ.)
2" or 3"
height above
finished floor
fig. 1.3 Discharge elbow for minimum footprint
Drain connection
Suction guide
System inlet
Recommended field
pressure gauge
piping arrangement
Flo-Trex valve
Hangers support the weight
of the filled piping, pumps
and fittings
Pipe hanger (typ.)
see specification for
size and type
System outlet
Split coupler
Flush line
fig. 1.4 With additional pipe supports
Drain connection
Suction guide
Neoprene
isolation pad
System inlet
Recommended field
pressure gauge piping
arrangement
Pipe support
Flo-Trex valve
Pet cock
(typ.)
Pipe hanger (typ.)
see specification for
size and type
System outlet
Split
coupler
Flush line
2" or 3"
height above
finished floor
Hangers support the
weight of the filled piping,
pumps and fittings
fig. 1.5 Floor saddle support

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
9
fig. 1.6 Additional floor support
GAP
fig. 1.7 With stanchion plates
Isolation Pads
Stanchion plates
fig.1.8 Seismic region installation
Seismically rated snubbers or pads and
conrete foundation
Stanchion plates
fig. 1.9 Mounting in grooved pipe systems
fig. 1.10 Motor lifting hook supported
fig. 1.11 Mounted on rigid base without flexible connectors
fig. 1.12 Motor and integrated controls assembly can be ro-
tated in 90° increments to meet installation spacing
requirements
Dr
ain connection
Suction guide
System inlet
Recommended field
pressure gauge
piping arrangement Flo-Trex valve
Pet cock
(typ.)
Pipe hanger
(typ.) See
specification for
size and type
System outlet
Flush line
Gruvlok 7000 flex
coupling (typ.)
7700 butterfly
valve
Hangers support the weight of the
filled piping, pumps and fittings
Split
coupler

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
10
fig. 1.13 Clearance radius for d size chassis
15.7
(399)
20.7
(526)
≤105,0
o
29.5"typ
fig. 1.14 Tapped collection well on Design Envelope 4300
Design Envelope 4300
seal leaks or condensate
dr
ain hole. Plumb to drain
for area cleanliness.
fig. 1.15 Clearance note
1 m (36") clearance in
front of controls may be
required in your locale
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.
For d1 and d2 chassis ivs units, access door swings open (see
fig. 1.13). 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

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
11
2.2 precautions
The standard enclosure rating for Design Envelope
4300 and Design Envelope 4380 integrated controls
is ul type 12 or ul type 4x for outdoor applications. If
the pump is to be installed in a wet or dusty environment then a
higher enclosure rating may be required (contact Armstrong).
To avoid the inverter unit getting overheated, the
ambient temperature is not to exceed 133°f (45°c)
average daily temperature. Operating in higher
ambient temperatures will require derating of the inverter.
All electrical connections should be carried out by a
qualified and authorised electrician in accordance
with local site regulations and the latest issue of the
iee regulations.
Before removing the inverter cover, the system must
be disconnected from the mains supply. After
switching o, wait for at least 15 minutes for the
capacitors to discharge before opening the cover.
caution
High voltage testing (Megging) of the motor/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 Design Envelope pump if (by mistake) the on-
board inverter has not been grounded.
Since the leakage current is >3.5ma (approx 4-20ma),
reinforced Grounding must be established which is
required if en 50178 is to be complied with. Never use
elcb relays that are not suitable for dc fault currents (type a).
If elcb relays are used, they must be:
• Suitable for protecting equipment with a direct current con-
tent (dc) in the fault current (three-phase bridge rectifier)
• Suitable for power-up with short charging current to Ground
• Suitable for a high leakage current
2.2.2 start/stop of pump
The number of starts/stops via the mains voltage must not
exceed one-time per minute.
If a higher number of starts/stops is required then the start/
stop digital input must be used (mains voltage directly con-
nected). This is the preferred method of starting and stopping
Design Envelope Pumps.
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 Design Envelope
pumps is as follows:
1 ×20 0 -24 0v±10%
3 ×20 0 -24 0v± 10%
3 ×3 8 0 - 48 0v±10%
3 ×525 - 6 0 0v± 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.

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
12
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 6180 0-5-1
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
fig.2.2 Mains and grounding connections for a5 units
(200-240V - 1.5hp 1ph/5hp and below 3ph,
380-480V/525-600V - 10hp and below)
95
fig.2.3a Mains and grounding connections for b1 and b2
units (200-240V - 2 to 7.5hp 1ph/7.5 to 20hp
3ph, 380-480V - 15 to 40hp, 525-600V – 15 to
50hp)
95
fig.2.3b Mains and grounding con-
nections for c1 and c2 units
(200-240V – 25 to 60hp,
380-480V – 50 to 125hp,
525-600V – 60 to 125hp)
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
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
95
91
L1
92
L2
93
L3

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
13
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 ivs are configured as follows:
Relay 1 – alarm
• Terminal 01:Common
• Terminal 02:Normal Open 240v ac
• Terminal 03: Normal Closed 240v ac
Relay 2 – run status
• Terminal 04: Common
• Terminal 05: Normal Open 400v ac
• Terminal 06: Normal Closed 240v ac
fig.2.4 Relay contact details
The following illustrations identify the location of the relays
within specific inverter sizes:
The illustrations in figures 6, 7 and 8identify the location of the
relays within specific inverter sizes:
fig.2.5 Relay connection: terminals for a5, b1 and b2 units
fig.2.6 Relay connection terminals for c1 and c2 units
fig.2.7 Relay connection terminals for c1 and c2 units
01 02 03
04 05 06
AUX RELAY

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
14
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
Reserved for control module
3-Phase Power
input (1-ph
power: No 92 (l2)
connection)

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
15
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
110-way plug for
digital i/0
23-way plug for
rs485 bus
36-way plug for
analog i/0
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

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
16
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 4300 & 4380 Vertical
In-line pumping unit with ivs drive
17
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 sys-
tem, 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 (sup-
plied 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
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 auto-
mation system, connect connect rj-45 cable to
this port per fig. 2.10
CAN bus
Modbus
A = + Positive
B = - Negative
G = Ground
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
rs-485
6.1
6.2
bms
bms

installation &
operating instructions
Design Envelope 4300 & 4380 Vertical
In-line pumping unit with ivs drive
18
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 4300 & 4380 Vertical
In-line pumping unit with ivs drive
19
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 4300 & 4380 Vertical
In-line pumping unit with ivs drive
20
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
positions
x402 403 Warnings 2n/a uint32 —Refer to alarms table for bit
positions
xx404 405 Acknowledge
Warnings 2Yes uint32 —32-bit field corresponding to the
warning field