Related Manuals for Armstrong AGE4 D
Summary of Contents for Armstrong AGE4 D
- Page 1 AGE4 variable speed circulator AGE4(D) Installation and operating instructions File No: 10.8509iec Date: september 05, 2023 Supersedes: new Date: new...
- Page 2 AGE4(D) Installation and operating manual 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; Circulators: Commission Regulation No. 641/2009. For EEI see nameplate. Standard used: EN 16297‐1:2012; EN 16297‐2:2012; ...
-
Page 3: Table Of Contents
English (EN) Installation and operating manual TABLE OF CONTENTS 1 General information .......................... 3 Uses ................................ 3 Pump labeling ............................ 3 Pump maintenance, spare parts and decommissioning ................ 3 2 Safety .............................. 3 3 Tehnical specifications ........................ 4 Standards and protections ........................ 4 Pump medium ............................ 4 Temperatures and ambient humidity ....................... 5 Electrical specification .......................... 5 4 Pump installation .......................... 8 Installation into pipe lines ........................ 8 ... -
Page 4: General Information
GENERAL INFORMATION USES The AGE4 circulating pumps are used for the transfer 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 device. The pump constantly measures pressure and flow and adjusts the speed according to the set pump mode. The main purpose of the twin pump is uninterrupted operation if one of the pumps fails. Common hydraulic housing is equipped with a change‐over flap and two pump heads, separately connected to the electrical grid. PUMP LABELING AGE4 (D) 40/120 AGE4 Pump family (D) Twin pump 40 Nominal pipe diameter 120 Maximum head (in 0.1 m of H O) PUMP MAINTENANCE, SPARE PARTS AND DECOMMISSIONING Pumps are designed to operate without maintenance for several years. Spare parts will be available for at least 3 years from the warranty period expiration. This product and its components must be disposed of in an environmentally friendly manner. Use waste collection services, if this is not possible, contact the nearest ARMSTRONG Pumps Service or authorized repairers. SAFETY These instructions should be studied carefully before installing or operating the pump. They are meant to help you with installation, use and maintenance and to increase your safety. Installation should only be performed with regards to local standards and directives. Only qualified personnel should maintain and service these products. Failure in following these instructions can cause damage to the user or product and can void warranty. Safety functions are only guaranteed if the pump is installed, used and maintained as described in this manual. 3 ... -
Page 5: Tehnical Specifications
TEHNICAL SPECIFICATIONS STANDARDS AND PROTECTIONS Pumps are made in according to the following standards and protections: Protection class: Insulation class: Motor protection: IP44 F Thermal ‐ built in Installation specification Pump type Nominal pressure Fitting length [mm] AGE4 25‐60 180 AGE4 25‐100 180 AGE4 25‐120 180 AGE4 30‐60 180 AGE4 30‐100 180 Common AGE4 30‐120 180 hydraulics PN6 and AGE4 25‐60Z PN10 180 Common AGE4 25‐100Z 180 hydraulics PN6 and AGE4 25‐120Z 180 PN10 AGE4 30‐60Z 180 AGE4 30‐100Z ... -
Page 6: Temperatures And Ambient Humidity
TEMPERATURES AND AMBIENT HUMIDITY Permitted ambient and media temperature: Medium temperature [°C] Ambient temperature Relative ambient humidity [°C] min. max. Up to 25 2 110 30 2 100 < 95 % 35 2 90 40 2 80 Medium temperature should be higher or the same as ambient temperature, so that the condensate does not gather on pump surface. Operation outside recommended conditions may shorten pump lifetime and void the warranty. For AGE4 , the maximum ambient temperature is 40°C, and the temperature range of the medium is from +2°C to +65°C. ELECTRICAL SPECIFICATION POWER SUPPLY ... - Page 7 3.4.2.2 ANALOG INPUTS AND OUTPUTS (SET1, SET2, SET3) Connections can be used either as inputs or outputs, depending on how we set it. Pump has 3 connectors: SET1, SET2 and SET3. Electrical properties Input voltage –1 ‐ 32 VDC When used as input. Output voltage 0 – 12 VDC When used as an output. Max. 5 mA load on individual output. Module U: ~ 50 kΩ Open circuit detection – max source output impedance < 50 kΩ Input impedance Module C: ~ 100 kΩ 0.5 mA additional load for most configurations. Input sink current 0 – 33 mA Common sink on COM, if used as output. Galvanic isolation Voltage 4 kV up to 1 s, 275 V permanent. 3.4.2.3 RELAY OUTPUT Electrical properties Rated current 3 A Maximum voltage 250 VAC, 30 VDC Maximum power 300 VA 3.4.2.4 ETHERNET Electrical properties Connector RJ‐45, 10BASE‐T, 10 Mbit/s. ...
- Page 8 3.4.2.5 MODBUS Modbus specification Data protocol Modbus RTU Modbus connector Screwless terminals 2+1 pins. Modbus connection RS‐485 type Modbus wire Two‐wire + common Conductors: A, B and COM (Common). configuration Communication Integrated, 1/8 of Connect either via passive taps or daisy chain. transceiver standard load Maximum cable 1200 m length Slave address 1‐247 Default is 245, settable over Modbus. Line termination Not present Line termination is not integrated. For low speed/short distance, termination can be omitted. Otherwise, terminate the line externally on both ends. Supported 1200, 2400, 4800, 9600, Settable over Modbus register [default=19200]. transmission speeds ...
-
Page 9: Pump Installation
PUMP INSTALLATION INSTALLATION INTO PIPE LINES The pump must be installed into pipe lines with its electromotor axis in horizontal position (figure 1) and in one of the allowed positions (figure 2). Direction arrow on hydraulic housing shows direction of water flow. For pump to operate with minimal vibrations and noise, it is recommended to install pump in part of the pipe line without curves for at least 5 D (D = rated pipe diameter) from both side of hydraulic housing. Pump with suffix F is designed to be built with connecting flanges, using all screws. The connecting flanges are designed so the pump can be installed in PN6 or PN10 nominal pressure pipelines. Because of the combined flange design, washers must be used on the pump side, when installing the pump. Desired head orientation can be achieved by rotating the pump head according to the hydraulic housing (Picture 3). If the pump is already in the system with medium, it is necessary to first close valves before and after the pump, to rotate the head. Unscrewing four screws which hold the head attached to the hydraulic housing makes rotating possible. Before fixing head back on, pay special attention to the position of seal between hydraulic housing and head of the pump. Ambient around the pump should be dry and illuminated as appropriate and the pump should not be in direct contact with any objects. Pump seals prevents dust and particles from entering as prescribed by IP class. Make sure that the distribution box cover is mounted and that the cable glands are tightened and are sealing. Pump will provide the longest lifetime with ambient at room temperature and moderate medium temperature. Prolonged operation at elevated temperatures could increase wear. Aging is accelerated by high power and high temperatures. Before first run of the pump, the system must be filed with medium and evacuated. Pump must have pressure on the suction side to operate properly. On the first run it is possible for the pump to make noise until it is automatically evacuated. Misconnection or overload could cause pump shutdown or even permanent damage. Pumps might be heavy. Provide yourself help if needed. Pump must not be used in the safety pipelines. Pump should not be used as a holder during welding! When reassembling, care should be taken to ensure seal fit. Failing that, water could cause damage to pumps internal parts. Drains between pump motor housing and hydraulic housing must be left free (should not be thermally insulated), as it could interfere with cooling and condense drainage (figure 1 . ... -
Page 10: Electrical Installation
ELECTRICAL INSTALLATION Electrical connection is done with connector supplied with the pump. Markings Descriptions L 230 VAC, electric power supply N PE Safety ground The pump has a built‐in over current fuse and protection, temperature protection and basic overvoltage protection. It doesn’t need an additional thermal protection switch. Connection leads should be capable of carrying rated power and should be properly fused. Ground lead connection is essential for safety. It should be connected first. Grounding is only meant for pump safety. Pipes should be grounded separately. Connection of the pump must be carried out by qualified personnel, Connection of the connecting cable 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, CONNECTION INSTRUCTION DIGITAL/ANALOG INPUTS/OUTPUTS, RELAY OUTPUT, MODBUS (RS‐485) Electrical properties Cross section 0,33 – 2,08 mm (14 – 22 AWG) Strip length 7,5 – 8,5 mm More on figure 4 ETHERNET, MODBUS 9 ... -
Page 11: Setup And Operation
SETUP AND OPERATION CONTROL AND FUNCTIONS All pumps feature: Display panel ‐ it controls and overviews pump modes, parameters and on/off status. Variant AGE4(D) features: Digital input RUN – to start/stop the pump. Relay output ‐ signalizes pumps status. Variant AGE4(D) features: Digital inputs: RUN – to start/stop the pump, MAX to run pump at maximum head or maximum speed (Input MAX works only in combination with input RUN – look at priorities!), MIN to run pump at minimum head or minimum speed. 0‐10 V analog input for changing reference point. Two relay outputs ‐ signalizes pumps status. Variant AGE4(D) features: 10‐step switch ‐ it allows us to change relay output, analog inputs/outputs and resetting the pumps communication configuration. Analog inputs ‐ gives us control over the pump (start, stop, MAX II. curve, min. curve, 0 – 10 V, 4 – 20 mA,…). Analog outputs ‐ are used for getting analog information about the pump’s performance (errors, speed, mode, flow, height). Relay output ‐ signalizes pumps status. Ethernet connection ‐ offers control over all pump functions and settings (pumps variables, digital inputs, error overview). Modbus connection ‐ gives us the overview of all parameters and settings (pumps variables, analog inputs/outputs, error overview). 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. Pump control panel and Priority ... - Page 12 DISPLAY PANEL With the use of the display panel, you can control and overview pump modes, on/off control, pump parameters and errors. To see how pump modes work, see chapter 5.2 Operation. 1. Bar graph display of pump parameters 2. Numerical display of values 3. Unit display 4. Display of the currently selected mode 5. Night mode 6. key 7. key 8. key 5.1.1.1 KEY FUNCTIONS Key Short press: Scrolling through parameters downwards when not changing parameter values, scrolling through modes downwards when mode selection is selected, changing parameters downwards when setting parameter values. Long press: 3 seconds together with turns on night mode, 3 seconds together with ...
- Page 13 Key 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: 3 seconds together with puts us in night mode, 5 seconds together with and keys to restore pump to factory settings. 5.1.1.2 TURNING ON AND OFF On first start up the pump will operate with factory settings in automatic mode. With subsequent start‐ups, the pump will operate with the last settings that were set prior to its shut‐down. To switch the pump off, press and hold the key for 5 seconds, until OFF is shown on the display. When the pump is switched off, the numerical display shows OFF. To turn the pump on, press the key briefly. 5.1.1.3 PUMP MODES AND PARAMETERS For transition between modes, we hold the key for 3 seconds and then select the mode in which we wish the pump to operate with or keys. We confirm the selection with the key. After confirming the mode, the parameter, which can be set, will automatically be displayed and blink (except for auto mode). If necessary, we set the parameter value with and keys, then confirm the setting with the key or just press the key to accept the given parameter. We can scroll through the parameters within a mode with ...
- Page 14 RELAY OUTPUT Relay output configuration is only possible in variant AGE4(D). Configuration S module Function description U module C module Fault Default for Default for The relay is in active position only when the pump is (error) Relay 2 Relay 2 powered up and an error is present. The relay is in active position when the pump is Default for Default for powered up and no error is present. If an error Ready Default Relay 1 Relay 1 occurs, relay will deactivate. The relay is in active position when the pump is powered up and running. If the pump is stopped or Run an error occurs, relay will deactivate. No function Relay is always in deactivated position. Always on ...
- Page 15 Input/Output Function Function description Turning the pump on/off. By default activating with SET1 Run [Default ‐ Mode 1] connection to SET3. MAX II/Min [Default ‐ Mode Set the pump to MAX II. settings when SET1 is active and to SET2 1] min. settings when SET1 is inactive. 10 V voltage output used for activating SET 1 and SET2 by SET3 FB [Default ‐ Mode 1] connecting them to SET3. 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. Mode switch Function Description position 0 Free configuration Terminal functions are configured over Ethernet interface. SET1 = RUN input SET2 = MAX input 1 Mode 1 SET3 = FB (10.5 V) output, used to supply RUN and MAX inputs. External voltage source can also be used. RS‐485 = Modbus interface. SET1 = RUN input SET2 = SPEED input 2 Mode 2 ...
- Page 16 ETHERNET The pump has a built‐in web server which allows you to access your pump directly via an existing Ethernet connection. The default address for access to the pump is "AGE4pump /" or 192.168.0.245/ The web server uses HTML pages to set/view: Regulation mode settings, regulation parameters (power, RPM, head, flow), relay settings, external control inputs settings, current and previews error, pump statistics (power consumption, run time and other). MODBUS Pump has built in Modbus client, through which we can access pump information using the RS 485 standard or ETHERNET (TCP/IP). Modbus allows us to set and view: Regulation mode settings, regulation parameters (power, RPM, head, flow), relay settings, external control inputs settings, current and previews error, pump statistics (power consumption, run time and other). RESETTING PUMP TO FACTORY SETTINGS For resetting the pump to factory settings all three buttons must be held for 5 seconds. This way the pump will set itself to automatic mode, delete previous height and power settings and unlock setting pump operation (if locked). Resetting of communications module needs following steps: 1. Disconnecting power from pump, 2. set the 10‐step switch to number 9 (or 8 for left twin pump), ...
-
Page 17: Operation
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 system. By doing so, the pump finds the optimal operating position. This mode is recommended in most systems. The parameters cannot be set; they can only be scrolled through. Proportional pressure The pump maintains the pressure with relation to the current flow. The pressure is equal to the set pressure (Hset on the drawing) at maximum power; at 0 flow it is equal to HQ % (default 50%, HQ % can be set on the pump webpage) of the set pressure. In between, the pressure changes linearly, relative to the flow. In regulated mode we can only set the pump pressure (Hset on the drawing). We can only scroll through the other parameters. Constant pressure The pump maintains the currently set pressure (Hset on the drawing), from 0 flow to maximum power, where the pressure begins to drop. Hset At constant pressure, we can only set the pressure (Hset on the drawing) which the pump Min. will maintain. We can only scroll through the other parameters. Constant speed The pump operates with the currently set speed (RPMset on the drawing). ... - Page 18 TWIN PUMP OPERATION Twin pumps have double hydraulic housing with integrated check valve, which automatically turns based on flow, and two separated motors. AGE4(D) 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 the control logic exchanges pumps for operation with time interval of ≤ 24 h. AGE4(D) pumps communicate with each other and have the following features: ‐ Alternating operation: One pump is operating while the other one is on standby. Pumps switch their role every 24 hours or when an error occurs on one pump. ‐ Duplex communication connection: Screened cable with line cross section 2x0.25mm , 90°C resistant and not longer than 1m must be used for duplex connection. One line of a cable is connected to COM/0V on both pumps. The other line of a cable is: ‐on one pump (primary pump) it is connected to MAX/DPLX1 and on the other pump (secondary pump) line is connected to MIN/DPLX2. Our duplex pumps with U module are already equipped with suitable cable which is correctly connected! When duplex communication is used, digital inputs MAX and MIN are disabled. AGE4(D) pumps communicate with each other and have the following features: ‐ Alternating operation [default setting] – One pump is operating while the other one is on standby. Pumps switch their role every 24 hours or when an error occurs on one pump. ‐ Backup operation – One pump operates constantly and the other one is on standby. If an error occurs on the operating pump the one on standby will automatically start working. This mode can be set up by turning off the pump that we wish to be on standby. That is done by holding the button for 5 seconds. Parallel operation – Both pumps work at the same time with the same settings of constant pressure. This mode is used when greater flow than one single pump can output is needed. When the first pump hits its flow limit the second one turns on and compliments the first to reach desired flow. This mode is activated when we set both pumps to constant pressure mode. Night mode is not recommended in this mode of operation. 17 ...
-
Page 19: Error And Troubleshooting
ERROR AND TROUBLESHOOTING If pump failure occurs, the error code will appear on the display. Error code Description Probable cause E1x Load errors E10 (dry) Low motor load Low load detected. Pump is running dry. E11 High motor load Motor might be faulty or viscous medium is present. E2x Protection active Circuit is too hot and power was reduced to less than 2/3 of rated E22 (hot) Converter temperature limit power. Converter temperature E23 Circuit is too hot to run, pump stopped protection E24 Converter overcurrent Hardware overcurrent protection triggered. E25 Overvoltage Line voltage is too high E26 Undervoltage Line voltage is too low for proper operation. E27 PFC Overcurrent Power correction circuit current cannot be controlled E3x Pump errors ... - Page 20 PUMP CURVES 19 ...
- Page 21 PICTURES Picture 1 Picture 2 20 ...
- Page 22 Picture 3 Picture 4 21 ...
- Page 23 Guarantee Retailer : Retail company : Date sold Guarantee : Product name : Serial number Guarantee period 24 months Manufacturer Declaration on guarantee and terms of guarantee Manufacturer declares: That the product conforms to the prescribed/declared quality. That the product will operate faultlessly within the terms of guarantee if the technical instructions provided are observed by user. That he will repair faults and shortcomings at his own expense caused by eventually differences between the actual and prescribed/declared quality or those due to which the product does not operate faultlessly or the manufacturer will replace the product. Cost from the previous paragraph for repairing or replacing the product are valid for material, spare parts, work and shipping. ...
- Page 24 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,...