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Armstrong AGE4 Installation And Operating Instructions Manual

Variable speed circulator
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AGE4 variable
speed circulator
AGE4(D) high power
Installation and
operating instructions
File No: 10.8506iec
Date: july 18, 2022
Supersedes: new
Date: new

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  • Page 1 AGE4 variable speed circulator AGE4(D) high power Installation and operating instructions File No: 10.8506iec Date: july 18, 2022 Supersedes: new Date: new...
  • Page 3 EN: Compliance of the product with EU standards: Machinery directive (2006/42/EC). Standard used: EN 809; Low Voltage (2014/35/EU). Standard used: EN 60335-1; EN 60335-2-51; Electromagnetic compatibility (2014/30/EU) Standard used: EN 55014-1; EN 55014-2; EN 61000-3-2; EN 61000-3-3; Ecodesign Directive (2009/125/EC) Standard used: EN 16297-1:2012;...

  • Page 4: Table Of Contents

    English (EN) Installation and operating manual TABLE OF CONTENTS General information ..........................5 Uses ................................5 Pump labeling ............................... 5 Pump maintenance, spare parts and decommissioning ................5 Safety ..............................5 Technical specifications .......................... 6 Standards and protections ..........................6 Pump medium ...............................

  • Page 5: General Information

    GENERAL INFORMATION USES The AGE4, AGE4 Z and the AGE4D wet rotor circulator are used for the circulation of liquid medium within systems for hot-water heating, air-conditioning and ventilation. They are designed as single or twin variable-speed pumping aggregates where the speed is regulated by electronic on board controller. The pump constantly measures pressure and flow and adjusts the speed according to the set pump mode.

  • Page 6: Technical Specifications

    Thermal - built in Installation specification Pump type Nominal pressure Fitting length [mm] AGE4 (D) 32-120 AGE4 (D) (Z) 40-80 AGE4 (D) (Z) 40-120 AGE4 (D) 40-180 AGE4 (D) (Z) 50-80 AGE4 (D) (Z) 50-120 Common hydraulics AGE4 (D) 50-180...

  • Page 7: Electrical Specification

    Voltage 4 kV up to 1 s, 275 V permanent. 3.4.2.3 RELAY OUTPUT Electrical properties Pump type AGE4 with power rating < 850 W AGE4 with power rating > 850 W Rated current MAX IIimum voltage 250 VAC, 30 VDC...
  • Page 8 3.4.2.4 ETHERNET Electrical properties Connector RJ-45, 10BASE-T, 10 Mbit/s. -Web server (port 80) Services -Software update through web interface. - Modbusa RTU through TCP/IP Default IP address 192.168.0.245 (on twin model AGE4D, the second head IP is 192.168.0.246) LED1 Ethernet visual Slowly blinking if module is on.
  • Page 9 3.4.2.7 MODBUS RTU Modbus RTU over RS-485 Slave address 1-247 See section 6.5 Speed, parity and address. [default=245] Maximum Modbus 256 bytes Including address (1) and CRC (2) bytes. packet size Supported baud rates 1200, 2400, 4800, 9600, Settable over Modbus register. 19200, 38400 Settable over Web interface (tab “Network”).

  • Page 10: Pump Installation

    PUMP INSTALLATION 4.1 MECHANICAL INSTALLATION INTO SYSTEM PIPEWORK The pump is packed in a double cardboard box to ensure protection during transport and handling in the plantroom. Once the box is open, use the plastic handles to lift the pump out of the box or lift it holding the drive heat sink. Pumps are designed to be mounted on the pipework with connecting flanges using screws in each flanges holes to ensure water tightness between the pump and the mating pipwork.

  • Page 11: Hydraulic Installation Into System

    4.2 HYDRAULIC INSTALLATION INTO SYSTEM The pump is designed to be installed into the pipework only in certain orientation, this is to avoid any air to be trapped inside the pump and risk of damaging the bearings or overheating the pump. Fig.3 To ensure the pump delivers the required flow and pressure, the pipework designer should also consider a minimum length of pipwework to be straight (without bends) for 5-10 D (D = rated pipe diameter) from the flanges on the inlet...

  • Page 12: Electrical Installation

    Misconnection or overload could cause pump shutdown or even permanent damage. Pumps might be heavy. Ask for some assistance and help if needed, Pumps must not be used in the safety pipelines, Pumps should not be used as a holder during welding! When reassembling, care should be taken to ensure seal fit.

  • Page 13: Bms Communication And Controls Installation

    Connection of the pump must be carried out by qualified personnel, Connection of the power cables must be done in a manner that ensures it is never in contact with the casing of the device, due to the high temperatures of the casing, This appliance cannot be used by children aged from 8 years and above and persons with reduced physical, sensory or mental capabilities or lack of experience and knowledge if they have been given supervision or instruction concerning use of the appliance in a safe way and understand the hazards...
  • Page 14 Normally open relay contact. Closes when relay is active. Terminal layout with factory configuration For all AGE4 with motor rated power > 200W NOTE: To maintain pump IP (ingress protection), the network cable should be pulled through the gland inlet and then crimped to a connector.

  • Page 15: Setup And Operation

    WARNING! If voltages over 24 V AC/DC are possible on NO, C, NC terminals: Wires should be routed so no wire crosses the center barrier. Relay cable (NO, C, NC) must be separated from all other wiring with reinforced insulation. Cable outer layer must not be stripped longer than 15 mm. See “Cabling preparation”...

  • Page 16: Priority Of Commands And Settings

    5.2 PRIORITY OF COMMANDS AND SETTINGS Several signals will influence the pump operation. For this reason, settings have different priorities as shown in the table below. If two or more functions are active at the same time, the one with highest priority will take precedence.
  • Page 17 5.2.1. DISPLAY PANEL The display and local control panel can be used to control and overview pump modes, on/off control, pump parameters and errors. To see how pump modes work, see chapte 5.2 Operation. 1. Bar graph display of pump parameters 2.
  • Page 18 Short press: Scrolling through parameters upwards when not changing parameter values, Scrolling through modes upwards when mode selection is selected, Changing parameters upwards when setting parameter values. Long press: seconds together with puts the pump in night mode, seconds together with keys to restore pump to factory settings.
  • Page 19 5.2.2 RELAYS OUTPUTS Configuration Function description Fault The relay is in active position only when the pump is powered up and an error is present. Ready [Default] The relay is in active position when the pump is powered up and no error is present.
  • Page 20 5.2.5 10-STEP SWITCH There is a mode selection rotary switch in the terminal box. It can be rotated by gently inserting a screwdriver into the arrow mark on top and rotating the switch to desired value. Switch setting is used when the pump turns on! More details about different modes can be found in communications manual.
  • Page 21 5.2.6 RESETTING PUMP TO FACTORY SETTINGS For resetting the pump to factory default settings all three buttons ( ) must be held for 5 seconds. The pump will reset to automatic mode, delete previous duty head settings and power settings and unlock setting pump operation (if previously locked).
  • Page 24 5.4 MODE 2 (0..10V)
  • Page 25 RELAYS OUTPUT...
  • Page 26 PUMP OPERATION The pump can operate in 5 different modes. We can set the pump in the most appropriate mode, depending on the system where the pump operates. The pump modes: Automatic mode (factory default), Proportional pressure, Constant pressure, Constant speed, Combined mode (all mode indicators are off) Automatic mode In automatic mode the pump automatically sets the operating pressure, depending on the hydraulic...
  • Page 27 Twin pump operation Twin pumps have double hydraulic housing with integrated check valve, which automaticaly turns based on flow, and two separated motors. AGE4D pumps do not have a control logic that ensures the continuous operation of at least one pump - the control logic must be carried out by the customer / user himself. It is recommended that AGE4D pumps communicate with each other and have the following features: Alternating operation [default setting] –...
  • Page 28 5.8 BMS COMMUNICATION OVER MODBUS 5.7.1 MODBUS RTU OVER RS-485 AGE4 pump is a Modbus RTU slave. Typically, only one master device is connected to the serial bus, and one or several slaves are also connected to the bus. 5.7.2 MODBUS OVER ETHERNET Modbus device is available at port 502.
  • Page 29 5.7.3 REGISTER OVERVIEW AGE4 Modbus RTU registers are grouped in the following register blocks: Start Register block Readable/Writeable Description address BMS module configuration Configuration of the BMS module BMS module status Status registers of BMS module AGE4 Pump control Pump control registers...
  • Page 31 5.7.5 BMS MODULE STATUS REGISTERS Registers in this block are read with either function codes 0x03 or 0x04. They are read-only. This block can be used for various kinds of fault finding. Address Register name Resolution Description 021..022 RESERVED SoftwareVersion BMS Module software version 024..029 RESERVED...
  • Page 32 5.7.7 PUMP STATUS REGISTERS Registers in this block can be read by means of function codes 0x03 and/or 0x04. They are read-only.
  • Page 33 5.7.8 PUMP DATA REGISTERS Registers in this block can be read by means of function codes 0x03 and/or 0x04. They are read-only.
  • Page 34 Product model number: 321 Application software: 2.286_BACNET Application firmware revision: 2.286_BACNET BACnet protocol revision: 19 The AGE4 pumps enables BACnet MS/TP communication with compatible pumps. BACnet Standardized Device Profile (Annex L): BACnet Operator Workstation (B-OWS) BACnet Advanced Operator Workstation (B-AWS)
  • Page 35 5.8.1 DATA LINK LAYER OPTIONS MS/TP master (Clause 9), baud rate(s): Configuration over Web interface (see tab “Net”), to reset to default, see section “ 5.2.5” DEVICE ADDRESS BINDING: Is static device binding supported? (This is currently necessary for two-way communication with MS/TP slaves and certain other devices.) NETWORKING OPTIONS: None SECURITY OPTIONS:...
  • Page 36 5.8.2 ANALOG INPUTS (OBJECT TYPE 0) NOTE: Values are read-only 5.8.3 ANALOG OUTPUTS (OBJECT TYPE 1)
  • Page 37 5.8.3 BINARY INPUTS (OBJECT TYPE 3) NOTE: Values are read-only 5.8.3 BINARY OUTPUTS (OBJECT TYPE 4)

  • Page 38: Error And Troubleshooting

    There are several possible connection configurations. Not all functions can be used simultaneously due to limited amount of outputs, inputs and inlet glands. Typical configurations - on/off + 0..10V - on/off + 0..10 V + relay outputs - on/off + 0..10 V + relay outputs + MODBUS RTU - on/off + Modbus RTU + Relay outputs - Modbus RTU + Relay outputs - on/off + BACnet MS/TP...
  • Page 40 t o r o n t o 23 bertrand avenue, toronto, ontario, canada, m1l 2p3 +1 416 755 2291 b u f fa lo 93 east avenue, north tonawanda, new york, u.s.a., 14120 - 6594 +1 7 16 693 8813 d r o i t w i c h s pa pointon way, stonebridge cross business park, droitwich spa,...

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