Armstrong AGE4 User manual

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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EN: Compliance of the product with EU standards:
xMachinery directive (2006/42/EC).
Standard used: EN 809;
xLow Voltage (2014/35/EU).
Standard used: EN 60335-1; EN 60335-2-51;
xElectromagnetic compatibility (2014/30/EU)
Standard used: EN 55014-1; EN 55014-2; EN 61000-3-2; EN 61000-3-3;
xEcodesign Directive (2009/125/EC)
Standard used: EN 16297-1:2012;
xCirculators:Commission Regulation No. 641/2009.
For EEI see nameplate.
Standard used: EN 16297-1:2012; EN 16297-2:2012;

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English (EN) Installation and operating manual
TABLE OF CONTENTS
1 General information ...............................................................................................................................5
1.1 Uses...............................................................................................................................................................5
1.2 Pump labeling ................................................................................................................. ..............................5
1.3 Pump maintenance, spare parts and decommissioning...............................................................................5
2 Safety ......................................................................................................................................................5
3 Technical specifications ..........................................................................................................................6
3.1 Standards and protections............................................................................................................................6
3.2 Pump medium...............................................................................................................................................6
3.3 Temperatures and ambient humidity...........................................................................................................6
3.4 Electrical specification ..................................................................................................................................7
4 Pump installation ..................................................................................................................................10
4.1 Mechanical Installation into system pipework ...........................................................................................10
4.2 Hydraulic Installation into system...............................................................................................................11
4.3 Electrical installation...................................................................................................................................12
4.4 BMS COMMUNICATION and controls installation ......................................................................................13
5 Setup and operation .............................................................................................................................15
5.1 Control and functions .................................................................................................................................15
5.2 Priority of commands and Settings.............................................................................................................16
6 Error and Troubleshooting....................................................................................................................38
Symbols used in this manual:
Warning:
Safety precautions which, if ignored could cause personal injury or machine damage
Notes:
Tips that could ease pump handling.

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1GENERAL INFORMATION
1.1 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.
C
Start/stop input 9
Relay ouput 2x
Max/min input 9
0-10V input 9
4-20mA input 9
PWM input 9
Modbus (RS485 or
TCP/IP) 9
Bacnet MS/TP 9
Web server 9
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 main.
1.2 PUMP LABELING
AGE4 (D) 40-120
AGE4 Pump family
(D) Twin pump
40 Nominal pipe diameter
120 MAX head (in 0.1 m of H2O)
1.3 PUMP MAINTENANCE, SPARE PARTS AND DECOMMISSIONING
Pumps are designed to operate without maintenance for several years. 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 ensure 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 put the user safety at risk, can cause damage to the 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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3TECHNICAL SPECIFICATIONS
3.1 STANDARDS AND PROTECTIONS
Pumps are made in according to the following standards and protections:
Protection class: Insulation class: Motor protection:
IP44 180 (H) Thermal - built in
Installation specification
Pump type Nominal pressure Fitting length [mm]
AGE4 (D) 32-120
Common hydraulics
PN6 and 10
220
AGE4 (D) (Z) 40-80 220
AGE4 (D) (Z) 40-120 250
AGE4 (D) 40-180 250
AGE4 (D) (Z) 50-80 280
AGE4 (D) (Z) 50-120 280
AGE4 (D) 50-180 280
AGE4 (D) 65-80 340
AGE4 (D) 65-120 340
AGE4 (D) 65-180 340
AGE4 (D) 80-80 360
AGE4 (D) 80-120 360
AGE4 (D) 100-120 450
3.2 PUMP MEDIUM
Pump medium can be pure water or a mixture of pure water and glycol, which is appropriate for heating or chilled
system. The medium must be free from aggressive or corrosive additives, free from mixtures of mineral oils and solid or
fibrous particles. The pump should not be used for pumping flammable, corrosive media and in an corrosive atmosphere.
Permanent magnet rotor inside the pump is prone to accumulating magnetic particles 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 covered by the warranty. To
ensure the pump is operating in optimal condition and eliminate any presence of magnetite in the system we
recommend the use of magnetite filter.
3.3 TEMPERATURES AND AMBIENT HUMIDITY
Permitted ambient and media temperature:
Ambient temperature
[°C]
Medium temperature [°C] Relative ambient humidity
min. max.
Up to 25 -10 110
<95 %
Up to 30 -10 100
Up to 35 -10 90
Up to 40 -10 80
xMedium temperature should be higher or the same as ambient temperature, so that the
condensate does not gather on pump surface.
xOperation outside allowed conditions may shorten pump lifetime and void the warranty.

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3.4 ELECTRICAL SPECIFICATION
3.4.1 POWER SUPPLY
Electrical ratings
Pump Rated
voltage
Rated
power
[W]
Rated
current [A]
Rated current
(IMAX II) [A] Startup
AGE4 (D) 32-120
230 VAC ±
15 %, 47-
63Hz
Pumps can
operate at
reduced
voltage with
limited
power
(P=IMAX II*U)
370 1.8 6
Build-in
startup
circuit.
AGE4 (D) (Z) 40-80 270 1.3 6
AGE4 (D) (Z) 40-120 480 2.3 6
AGE4 (D) 40-180 680 3.4 6
AGE4 (D) (Z) 50-80 370 1.7 6
AGE4 (D) (Z) 50-120 560 2.5 6
AGE4 (D) 50-180 830 3.6 6
AGE4 (D) 65-80 560 2.6 6
AGE4 (D) 65-120 810 3.5 6
AGE4 (D) 65-180 1550 5.4 6.6
AGE4 (D) 80-80 800 3.5 6
AGE4 (D) 80-120 1380 5.0 6
AGE4 100-120 1550 5.4 6.6
3.4.2 ELECTRICAL SPECIFICATIONS OF INPUTS, OUTPUTS AND COMMUNICATION
To see inputs, outputs and communication functions see chapter 5 Setup and operation. Detailed specifications about
used protocols are described in communications manual.
3.4.2.1 DIGITAL INPUT (RUN, 0V)
Available on all AGE4 models
Electrical properties
Resistance of the closed loop 100 ɏ
3.4.2.2 ANALOG INPUTS AND OUTPUTS (SET1,SET2,SET3)
Electrical properties
Input voltage –1 - 32 VDC When used as input.
Output voltage 0 - 12 VDC When used as an output 5 mA load on individual output.
Input impedance ~100 kё0.5 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
Pump type AGE4 with power rating < 850 W AGE4 with power rating > 850 W
Rated current 3 A 8 A
MAX IIimum voltage 250 VAC, 30 VDC 250 VAC, 30 VDC
MAX IIimum power 300 VA 500 VA
xOnly potential-free contact can be connected to this input.

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3.4.2.4 ETHERNET
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 (on twin model AGE4D, the second head IP is 192.168.0.246)
Ethernet visual
diagnostics
LED1
Slowly blinking if module is on. Lights up when the connection is established.
LED2
3.4.2.5 MODBUS
Modbus over Ethernet
Server address 192.168.0.245:502 IP address is the same as for pump web server,
port is fixed as 502
Device address 245 Default value, can be changed over Modbus
Data format and
protocols
x Modbus TCP
x Modbus RTU over TCP
x Modbus UDP
x Modbus RTU over UDP
Protocol is automatically selected according to
established connection and received request.
3.4.2.6 RS-485
RS-485
Connector type Screwless terminals 2+1 pins. See section 3.1 Terminals
Data protocol - Modbus RTU
- BACnet MS/TP
Only one at a time.
Selectable over Web interface (tab “Network”)
Bus wire configuration Two-wire + common Conductors: A, B and COM (Common).
See section 3.1 Terminals
Communication
transceiver
Integrated, 1/8 of
standard load
Connect either via passive taps or daisy chain.
Maximum cable length 1200 m See section 6.6 Termination
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
Up to 38400 baud See data for protocol used.
Start bits, data bits 1, 8 Fixed.
Visual diagnostics LED2 Flashing yellow when data reception detected.
Combined (OR) with Ethernet ACT function.
Maximum number of
devices
256 1/8 nominal load enables 256 devices, protocol limit
might be lower.
Isolation Common ground (COM)
with SET1, SET2 and
SET3.
Bus shares common ground with other signals.

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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
packet size
256 bytes Including address (1) and CRC (2) bytes.
Supported baud rates 1200, 2400, 4800, 9600,
19200, 38400
Settable over Modbus register.
Settable over Web interface (tab “Network”).
[default=19200]
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]
3.4.2.8 BACNET
BACnet MS/TP over RS-485
Device MAC address 1-127 Settable over Web interface (tab “Network”)
[default=1]
Maximum ADPU size 92 bytes
Supported baud rates 9600, 19200, 38400 Settable over Web interface (tab “Network”)
[default=38400]
Modbus over Ethernet
Server address 192.168.0.245:502 IP address is the same as for pump web
server, port is fixed as 502
Device address 245 Default value, can be changed over Modbus
Data format and
protocols
Modbus TCP
Modbus RTU over TCP
Modbus UDP
Modbus RTU over UDP
Protocol is automatically selected according
to established connection and received
request.
Analog signals (SET1, SET2, SET3)
Input voltage range -1..32 VDC When used as input.
Output voltage
source range
0..12 V When used as voltage output. 5 mA max. Load
allowed per output.
Input resistance ΕϭϬϬŬɏ 0.5 mA load is added for most configurations.
Output current sink
range
0..33 mA (4-20 mA) Current sink to COM if configured as current
output.
PWM input threshold ~3 V 5 mA current sink added.
PWM input frequency 0..10 kHz
PWM out frequency 75 Hz
Connection type Screwless terminals
Rating
- 230 VAC, 3 A, AC1
-32 VDC, 3 A

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4PUMPINSTALLATION
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. The pump flanges are designed so the pump can be installed
in PN6 or PN10 nominal pressure pipelines up to DN65. Because of the combined flange design, washers must be used
on the pump side, when installing the pump.
For the pump to operate with minimal vibrations and noise, it should be installed into the pipework with its axis (or shaft)
in horizontal position, as showed in figure 1.
The small rectangular openings at the base of the motor (showed on Fig.1, point A) are designed to prevent any
condenation forming inside the motor. These should be left open and not covered (for examples, pump clading should
not covers them).
Fig.1
Desired controls orientation can be achieved by rotating the pump head (pump positions shown in figure 3). Pump
head is mounted to hydraulic casting with four screws. By unscrewing those, the pump head can then be turned (Fig.2).
Fig.2
1. Unscrew the
pump head from
the pump casing
2. Gently pull the
head out a little. This is
to avoid damaging the
pump body gasket.
3. Rotate the head to
the desired orientation.
Note that the Electrical
connection should not be
facing up.