ITT PumpSmart PS220 User manual

PS220 Configuration & Operation Guide
Installation, Operation,
and Maintenance Manual
PumpSmart®Control Solutions PS220 v6

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide
1 PS220
Dear Valued Customer,
Congratulations on the purchase of your PumpSmart® PS220 variable
speed frequency drive.
Leveraging our 160+ years in pump design, manufacture, and operation,
ITT has one goal; improving the profitability of your plant. Our products
and services target your biggest issues of process uptime, maintenance,
and energy costs.
The PumpSmart® PS220 integrates an industrial strength variable frequen-
cy drive with years of pump control logic and testing. 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 can
keep your process running longer and eliminate unplanned repair activities.
By Right-Sizing your pumps 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 changing process control and protection for pumping systems.
From single pump applications to multi-pump applications, the PumpSmart® PS220 can accurately control to pressure,
flow, level, temperature or other process conditions.
For additional information on the PumpSmart PS220 review the configuration manual or visit www.ittmc.com.
Please take the time to review, understand the safe installation, operation and maintenance guidelines provided in the
ACS880 Hardware Manual, PS220 Configuration and Operation Guide and the Installation, Operation and Maintenance
instructions for the applied driven equipment.
The PS220 has been designed for safe and reliable operation when properly installed, applied and maintained in accor-
dance with the instructions in the ACS880 Hardware Manual and PS220 Configuration and Operation Guide. ITT Monitor-
ing and Control shall not be liable for physical injury, damage or delays caused by failure to follow these instructions.
Getting
Started

PS220 Configuration & Operation Guide
Getting
Started
PS220 Configuration & Operation Guide
PS220 2
Important Safety Reminder Section 1.0 Page 03
PS220 Wizards Section 2.0 Page 05
Basic Startup Section 2.1 Page 07
SmartFlow Section 2.2 Page 23
Process Control Section 2.3 Page 51
Pump and VFD Section 2.4 Page 72
protection
Multipump Section 2.5 Page 104
Multivariable Section 2.6 Page 120
Options and Features Section 3.0 Page 127
Appendices Page 172
Keypad Use A-1 Page 172
Fault Tracing A-2 Page 177
Parameter Listing A-3 Page 189
Basic Wiring & Installation
Multipump connections
Quick Reference
• Wall mount units A-4 Page 206
• Floor mount units

PS220 Configuration & Operation Guide
Getting
Started
PS220 Configuration & Operation Guide
3 PS220
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
Getting
Started
PS220 Configuration & Operation Guide
PS220 4
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
Wizard Menu
The PumpSmart PS220 has incorporated a timesaving Wizard Menu and an extremely versatile range of configurations to
make setup and operation incredibly easy. Instead of navigating through hundreds of parameters the ones needed are all
located in an easy access, intuitive menu structure.
Details on functions not covered in the wizards are listed in the options and features section. Water functions, I/O
Configuration, and parameter lock are covered in the options and features section.
The PS220 wizards have been designed to cover a wide range of common use applications. Unfortunately, they cannot
cover every use case. When reconfiguring the drive for a different setup it is highly recommended to restore the drive’s
parameters to factory settings.
Getting
Started
PS220 Configuration & Operation Guide
5 PS220
PS220 Configuration Menu
Basic Startup
SmartFlow
Process Control
Pump Protection
Multi-pump
Multivariable
Options & Features
Keypad Use
Fault Tracing
Parameter List
Appendix

PS220 Configuration & Operation Guide
PS220 6
Basic
Startup
PS220 Configuration & Operation Guide
THIS PAGE IS INTENTIONALLY LEFT BLANK

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7 PS220
Basic
Startup
Basic Startup
This section details how to setup your PumpSmart PS220 and configure it to operate in single pump speed control mode.
This is where the Motor Data, Motor ID Run, Direction Check and other basic setup options are performed. After complet-
ing this section you can continue setting up your system for SmartFlow, Process Control, Multi-pump, or other PumpSmart
options.
Step Description Parameters
Motor Setup 99.06
Drive data for the 99.07
First Motor Run ID is 99.08
entered here 99.09
99.10
Motor Setup
Perform the ID and
Check for proper
motor rotation
Start/Stop
Methods of starting 74.01
and stopping
Speed Range
MAX and MIN drive 30.11
speeds 30.12
Operating Mode
Selects the mode of
operation
Setpoint
Options for setting
a reference
1
2
3
4
5
6
Edit Motor ParametersBasic Drive Setup

PS220 Configuration & Operation Guide
PS220 8
PS220 Configuration & Operation Guide
Basic
Startup
Edit Motor Parameters
The PumpSmart PS220 variable frequency drive utilizes Direct Torque Control [DTC] rather than
a scalar speed control variable such as Volts/Hertz. Direct Torque Control provides more precise
speed control, hence more responsive and accurate control to your setpoint. Specific motor data
must be entered into the PumpSmart drive to enable it to properly control the motor using DTC.
Steps to be performed are:
1. Motor Setup
2. Motor Identification Run
3. Motor Jog for Direction
E-Stop/Permissive
The PS220 will not operate unless the
E-Stop/Permissive switch [DIIL] is closed.
This includes performing the Motor ID
Run. If not closed a warning message
will appear on the keypad display:
See Appendix A-4, Instrument Wiring,
for details on wiring this switch.
NOTE – The E-Stop/Permissive switch cannot
be defeated through parameter setting. If your
application does not use an E-Stop / Permissive
switch, DIIL can be bypassed physically inside the
PumpSmart unit. Refer to Appendix A-4,Instru-
ment Wiring, for details.

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9 PS220
Basic
Startup
Motor Setup
From the PS220 Configuration Menu select Basic
Startup; if this is the first time the drive has been
started then it will automatically open to the Basic
Startup wizard. Inside of Motor Setup the motor
data must be entered. The motor data will allow
the PumpSmart drive to characterize the motor
prior to its first startup. During characterization,
PumpSmart will automatically magnetize the
motor windings for 20 – 60 seconds to develop
a mathematical model of the motor. Entry of the
following parameters is all that is required.
Note – If the motor is replaced in the future, this
data must be re-entered and a new
characterization will be performed.
The information required for this section can be
found on the motor nameplate.
Enter the Motor Nominal Current (full load amps)
as found on the motor nameplate, along with the nominal voltage, and nominal frequency.
Enter the full load speed of the motor as found on the nameplate, not the nominal speed.
Enter the nominal power (hp or kW) of the motor; if you are using the default language of
English U.S., then the units of entry will be horsepower.
Example 1.1 – An 1800 RPM motor might have a full load speed of 1770 rpm.
Select Edit Adjust