Armstrong AGE4D User manual

AGE4 variable
speed circulator
AGE4(D)
Installation and
operating instructions
File No: 10.8509iec
Date: september 05, 2023
Supersedes: new
Date: new

AGE4(D)
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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;
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ENInstallationandoperatingmanual

2
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English(EN)Installationandoperatingmanual 
TABLEOFCONTENTS
1Generalinformation............................................................................................................................3
1.1Uses..........................................................................................................................................................3
1.2Pumplabeling...........................................................................................................................................3
1.3Pumpmaintenance,sparepartsanddecommissioning...........................................................................3
2Safety..................................................................................................................................................3
3Tehnicalspecifications........................................................................................................................4
3.1Standardsandprotections.......................................................................................................................4
3.2Pumpmedium..........................................................................................................................................4
3.3Temperaturesandambienthumidity.......................................................................................................5
3.4Electricalspecification..............................................................................................................................5
4Pumpinstallation................................................................................................................................8
4.1Installationintopipelines........................................................................................................................8
4.2Electricalinstallation................................................................................................................................9
4.3Connectioninstruction.............................................................................................................................9
5Setupandoperation.........................................................................................................................10
5.1Controlandfunctions.............................................................................................................................10
5.2Operation................................................................................................................................................16
6ErrorandTroubleshooting................................................................................................................18
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Pumpcurvesareontheendofthemanual.
Subjecttoalterations!
Symbolsusedinthismanual:
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Warning:
Safetyprecautionswhich,ifignoredcouldcausepersonalinjuryormachinerydamage
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Notes:
Tipsthatcouldeasepumphandling.

3
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1GENERALINFORMATION
1.1 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.
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1.2 PUMPLABELING
AGE4(D)40/120
AGE4Pumpfamily
(D)Twinpump
40Nominalpipediameter
120Maximumhead(in0.1mofH2O)
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1.3 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.
2SAFETY
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.
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4
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3TEHNICALSPECIFICATIONS
3.1 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
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Installationspecification
PumptypeNominalpressureFittinglength[mm]
AGE425‐60
Common
hydraulicsPN6and
PN10
Common
hydraulicsPN6and
PN10
180
AGE425‐100180
AGE425‐120180
AGE430‐60 180
AGE430‐100180
AGE430‐120180
AGE425‐60Z 180
AGE425‐100Z180
AGE425‐120Z180
AGE430‐60Z 180
AGE430‐100Z180
AGE430‐120Z180
AGE4D30‐60 180
AGE4D30‐100180
3.2 PUMPMEDIUM
Pumpmediumcanbepurewateroramixtureofpurewaterandglycol,whichisappropriateforcentralheating
system.WatermustmeetwaterqualitystandardVDI2035.Themediummustbefreefromaggressiveor
explosiveadditives,freefrommixturesofmineraloilsandsolidorfibrousparticles.Thepumpshouldnotbe
usedforpumpingflammable,explosivemediaandinanexplosiveatmosphere.
AGE4isdesignedexclusivelyforpumpingsanitarywater.
Permanentmagnetrotorinsidethepumpispronetoaccumulatingmagneticparticles(magnetite)onitssurface,
whichcanleadtoabrasionofbearingsandrotorcanorevenblockingtherotor.Althoughthepumpisbuiltina
waythattheeffectofmagneticparticlesisminimal,failuresofbearings,rotorcansandblockedrotorsarenota
subjectofclaims.
Toimprovepumpresistancetomagnetitewerecommendtheuseofmagnetitefilter.
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5
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3.3 TEMPERATURESANDAMBIENTHUMIDITY
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Permittedambientandmediatemperature:
Ambienttemperature
[°C]
Mediumtemperature[°C]Relativeambienthumidity
min.max.
Upto252110
<95%
302100
35290
40280
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Mediumtemperatureshouldbehigherorthesameasambienttemperature,sothatthe
condensatedoesnotgatheronpumpsurface.
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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.
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3.4 ELECTRICALSPECIFICATION
POWERSUPPLY
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Electricalproperties
PumpRatedvoltageRated
power[W]
Ratedcurrent
(Imax)[A]Startup
AGE4xx/60230VAC±15%,47‐63Hz
Pumpscanoperateat
reducedvoltagewithlimited
power(𝑃𝐼
 ⋅𝑈)
900,75
Build‐in
startup
circuit
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AGE4xx/1001801,5
AGE4xx/1201801,55
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ELECTRICALSPECIFICATIONSOFINPUTS,OUTPUTSANDCOMMUNICATION
Toseeinputs,outputsandcommunicationfunctionsseechapter5Setupandoperation.Notallfunctionsare
availableinallversions!
3.4.2.1 DIGITALINPUT(RUN,0V)
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Electricalproperties
Max.resistanceoftheclosedloop100Ω
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Onlypotential‐freecontactcanbeconnectedtothisinput.

6
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3.4.2.2 ANALOGINPUTSANDOUTPUTS(SET1,SET2,SET3)
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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.
InputimpedanceModuleU:~50kΩ Opencircuitdetection
–
maxsourceoutputimpedance<50kΩ
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.
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3.4.2.3 RELAYOUTPUT
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Electricalproperties
Ratedcurrent 3A
Maximumvoltage250VAC,30VDC
Maximumpower300VA
3.4.2.4 ETHERNET
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Electricalproperties
ConnectorRJ‐45, 10BASE‐T,10Mbit/s. 
Services
‐Webserver(port80)
‐Softwareupdatethroughwebinterface.
‐ModbusaRTUthroughTCP/IP
DefaultIPaddress192.168.0.245( 192.168.0.246forrightpump) 
EthernetvisualdiagnosticsLED1Slowlyblinkingifmoduleison.Lightsupwhentheconnectionis
established.
LED2
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7
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3.4.2.5 MODBUS

Modbusspecification
DataprotocolModbusRTU

ModbusconnectorScrewlessterminals2+1pins.
Modbusconnection
type
RS‐485

Modbuswire
configuration
Two‐wire+commonConductors:A,BandCOM(Common).

Communication
transceiver
Integrated,1/8of
standardload
Connecteitherviapassivetapsordaisychain.
Maximumcable
length
1200m

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
transmissionspeeds
1200,2400,4800,9600,
19200,38400baud
SettableoverModbusregister[default=19200].
Startbit1  Fixed.
Databits8  Fixed.
Stopbits 1or21stopbitminimum,upto2whenparitynot
enabled[default=1]
ParitybitEven/odd/none[default=Even]
Modbusvisual
diagnostics
LED2 Flashingyellowwhendatareceptiondetected.
Combined(OR)withEthernetACTfunction.
Maximumnumberof
Modbusdevices
247 LimitedbypossibleModbusaddressesto247.
1/8nominalloadenables256devices.
MaximumModbus
packetsize
256bytes  Includingaddress(1)andCRC(2)bytes.
IsolationCommonground(COM)
withSET1,SET2and
SET3.
Modbussharescommongroundwithother
signals.
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8
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4PUMPINSTALLATION
4.1 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
)
.
Hotmediumcancauseburns!Themotorcanalsoreachtemperaturesthatcouldcause
injury.


9

4.2 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,
4.3 CONNECTIONINSTRUCTION
DIGITAL/ANALOGINPUTS/OUTPUTS,RELAYOUTPUT,MODBUS(RS‐485)

Electricalproperties
Crosssection 0,33–2,08mm2(14–22AWG)
Striplength7,5–8,5mm
Moreonfigure4 . 
ETHERNET,MODBUS
