ITT PumpSmart PS220 User manual

Configuration &

Operation Manual

PumpSmart®Control Solutions PS220 v6.05

PS220 Configuration & Operation Guide

1 PS220

Getting

Started

Congratulations on the purchase of your PumpSmart® PS220 .

Leveraging our 160+ years in pump design, manufacture, and operation,

ITT Gould’s Pumps has one goal: improving the profitability of your plant

operations. Our products and services target your biggest issues to increase

process uptime, reduce maintenance costs, and lower operating energy

costs.

The PumpSmart® PS220 integrates a world leading ABB variable frequency

drive with decades of pump control logic, that has been field tested on tens

of thousands of applications worldwide. The PumpSmart® PS220 variable

speed pump control system provides real-time control and protection of

your pumps while also providing valuable process insight. By protecting

against unplanned pump failure due to process upsets, ITT Gould’s Pumps

can keep your process running longer and reduce and may eliminate

unplanned repair activities. In addition, through the “Right-Sizing” of your

pump to your system, we can reduce not only your energy consumption,

but the wear and tear on your pumps and process system.

Since 1999 the PumpSmart® patented logic has been the world leader in changing process control with pump protection

for pumping systems. From single pump applications to multi-pump applications, the PumpSmart® PS220 can accurately

control to Pressure, Flow, SmartFlow®, TDH, Level, and temperature with up to 6 pumps working together.

For additional information on the PumpSmart PS220 please take the time to review, and understand the safe installation,

operation and maintenance guidelines provided in the ABB ACS880 Hardware Manual or visit www.ITTMC.com.

The PS220 has been designed for safe and reliable operation when properly installed, applied, and maintained in accordance

with the instructions in the ACS880 Hardware Manual and PS220 Configuration and Operation Guide. ITT Monitoring and

Control shall not be liable for physical injury, damage, or delays caused by failure to follow these instructions.

PS220 Configuration & Operation Guide

PS220 2

Getting

Started

PumpSmart PS220 Wizards Page Number

1. Basic Startup

1. Edit Motor Parameters 09

2. Basic Drive Setup (Speed Control) 14

2. SmartFlow

1. Basic 22

2. Advanced 32

3. Smartflow Tune 37

3. Process Control

1. Process Control Mode 40

2. Sleep 47

3. Process PID Tuning 50

4. Pump & VFD Protection

1. Basic Pump Protection 52

2. Advanced Pump Protection 56

3. Secondary Protection 62

4. Condition Monitoring 64

1. Flow Bypass 70

5. VFD Protection 71

6. Protection Options 75

5. Multi-Pump 78

6. Multi Variable 82

7. Water Functions

1. Pump Cleaning 87

2. Snore 94

3. Pipe Cleaning 96

4. Pipe Fill 98

PS220 Configuration & Operation Guide

3 PS220

Getting

Started

PumpSmart PS220 Wizards Page Number

8. I/O Configuration 100

1. Analog Inputs/Outputs

1. Analog 101

2. Analog Outputs 105

2. Digital Inputs/Outputs 107

3. Relays 109

9. Parameter Restore 110

10. Parameter Lock 111

11. Miscellaneous

1. Speed Override 112

2. SmartControl (PID Torque) 115

3. Advanced Pressure Control 117

Functions & Features 119-120

Keypad Use 243

Fault Tracing

PS220 Pumping System Warnings/Alarms 248

PS220 Pumping System Faults 253

VFD Alarms and Faults 254

Parameter Listing 261

Wiring Diagrams 283

Eco Design Regulation 289

Fuse - Heat Dissipation 291

Hardware Technical Information 295

PS220 Configuration & Operation Guide

PS220 4

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PS220 Configuration & Operation Guide

5 PS220

Getting

Started

Products manufactured and furnished by ITT Monitoring and Control will provide safe, trouble-free service when properly

installed, maintained and operated. We have an extensive network of experienced sales and service professionals to assist

in maximizing your satisfaction with our products.

Safe installation, operation and maintenance of ITT’s equipment are essential end user responsibilities. The ACS880 Hard-

ware Manual and PS220 Configuration and Operation Guide identify specific safety risks that must be considered at all

times during the life of the product. Understanding and adhering to these safety warnings is mandatory to ensure person-

nel, property and/or the environment will not be harmed. Adherence to these warnings alone, however, is not sufficient;

it is expected that the end user will also comply with industry and corporate safety standards. Identifying and eliminating

unsafe installation, operation and maintenance practices is the responsibility of all individuals involved in the installation,

operation and maintenance of industrial equipment.

Safety Symbol and Signal Word Explanation:

IMPORTANT SAFETY REMINDER

This is the dangerous voltage alert symbol. It warns of high voltage which can cause death or physical

injury. Obey all safety messages that follow this symbol to avoid possible injury or death.

This is the safety alert symbol. It is used to alert you to potential personal injury hazards. Obey all safety

messages that follow this symbol to avoid possible injury or death.

DANGER indicates a hazardous situation which, if not avoided, will result in death or

serious injury.

DANGER

WARNING indicates a hazardous situation which, if not avoided, could result in death or

serious injury.

WARNING

CAUTION indicates a hazardous situation which, if not avoided, may result in minor or

moderate injury.

CAUTION

NOTICE used without the safety alert symbol addresses practices which, if not avoided, may

result in property damage.

NOTICE

PS220 Configuration & Operation Guide

PS220 6

Getting

Started

With respect to PumpSmart drives and the operation of pumping equipment the following risks bear reinforcement above

and beyond normal safety precautions:

Never work on the PS220 drive, the motor cable or the motor when main power is applied. After switching off

the input power, always wait 5 minutes to allow drive internal capacitors to discharge before working on the

drive, the motor or the motor cable. Failure to do so will result in serious injury or death.

DANGER

Do not work on control cables when power is applied to the drive or to external control circuits. Externally

supplied control circuits may cause dangerous voltages inside the drive even if the main power on the drive is

switched off. Failure to do so will result in serious injury or death.

DANGER

All electrical installation and maintenance work must be undertaken by a qualified electrician only. Failure to do

so could result in serious injury or death.

WARNING

Operation of any pumping system with a blocked suction and discharge must be avoided in all cases. Opera-

tion, even for a brief period under these conditions, can cause superheating of internal pumpage and result in a

violent explosion. All necessary measures must be taken by the end user to ensure this condition does not occur.

Failure to do so could result in serious injury or death.

WARNING

Never operate rotating equipment unless all protective coupling and shaft guards are in place. Personal injury

may occur if the driven equipment is operated without coupling and shaft guards. Failure to do so could result

in serious injury or death.

WARNING

Handle the unit carefully. The PS220 is heavy. Do not lift it alone.

Wall Mounted Units: Do not lift the PS220 by the front cover. Place the unit only on its back.

Floor Mounted Units: Lift the PS220 by the lifting lugs only. Do not tilt the unit. The unit will overturn from a tilt

of about 6 degrees. Use extreme caution when maneuvering a unit that has been placed on wheels.

Failure to do follow these instructions could result in serious injury or death or damage to the equipment

WARNING

PS220 Configuration & Operation Guide

7 PS220

Getting

Started

PumpSmart PS220 Wizard Menu

The PumpSmart PS220 utilizes a time saving versatile range of configurations to make initial setup incredibly easy. The

PS220 wizards have been designed to cover a wide range of common applications for pumping systems used around the

world.

The table below lists all of the Wizards that are in this section. Each section will describe the steps that you will need to

follow to properly configure the function(s) and will show step by step screen shots as you progress from beginning to

end. Additional information may also be shown, to assist you along the way, such as the table of all parameters used with

the function.

A thorough detailed explanation of each functions capability and use are in the individual Features & Function section in

this manual.

Details on functionality not covered in the Wizards are listed in the Functions and Features sections.

When reconfiguring the PumpSmart PS220 it is highly recommended to restore the parameters to the original factory

default settings. Please use the PARAMATER RESTORE assistant shown in the Menu Tree below.

PS220 Wizard Menu Tree

Basic Startup

SmartFlow

Process Control

Pump & VFD Protection

Multi-pump

Multivariable

Water Functions

I/O Configuration

Parameter Lock

Miscellaneous

Function & Features

Fault Tracing

Parameter Listing

PS220 Configuration & Operation Guide

PS220 8

Basic

Startup

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PS220 Configuration & Operation Guide

9 PS220

Basic

Startup

1. Basic Startup Wizard

The PumpSmart PS220’s default mode of operation utilizes the Electric

Motor connected and will run the Pump using the Basic Speed Control

Functionality. The Basic Startup will configure the PumpSmart PS220 with

the language you select, allow you to define the motor characteristic,

execute a Motor ID, and verify correct motor rotation. You will then select

the start/stop method, the operating speed range, and the method used

to send the speed set point reference for the system to work.

This procedure provides a baseline for all the PumpSmart functionality to

properly perform. It must be performed prior to any other functionality

can be configured.

This functionality can only be configured with the PumpSmart PS220

Configuration Wizard.

To access this Wizard, from the Home Screen follow the path:

Menu>PS220 Configuration>Basic Startup>

The steps that you will perform are as follows:

1. Configure the Motor Parameters.

2. Configure Basic Drive Setup information.

The Screen Shots that follow will show you step by step, from start to

finish as you progress, how to configure this functionality.

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