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.

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Getting

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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

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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

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PS220 Configuration & Operation Guide

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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

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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

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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

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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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Basic

Startup

1.1 Motor Parameter Configuration

Wizard

The PumpSmart PS220 will not operate unless the Electric Motor connected is

configured with all necessary information required.

To access this Wizard, from the Home Screen follow the path: Menu>PS220

Configuration>Basic Startup>Edit Motor Parameters>

The steps that you will perform are as follows:

1. Configure the Motor Setup

2. Perform the Motor ID Run

3. Perform a Motor Jog for Direction

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

you progress, how to configure this functionality.

1. Configure the Motor Information

All this information can usually be found on the Motor Nameplate that should be

physically attached to the Motor.

If the Nameplate is not available, you cannot proceed to any of the next steps.

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1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “ARROW DOWN”

1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “ARROW DOWN”

1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “ARROW DOWN”

1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “ARROW DOWN”

1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “ARROW DOWN”

1. “ARROW RIGHT” To change

2. “ARROWS” to change value

3. “Save”

4. “Next”

1. Configure the Supply voltage 2. Configure the Motor Full Load Amps/Current (FLA)

3. Configure the Motor Voltage 4. Configure the Motor frequency (50 or 60Hz)

5. Configure the Motor full load RPM (Slip Speed) 6. Configure the Motor nominal power

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Basic

Startup

2. Perform a Motor ID RUN

The PumpSmart PS220 drive uses specific motor details to create a mathematical model. This model en-

ables more accurate motor control and is created using the motor data you have just entered. The PS220

will be magnetizing the motor from 20 to 60 seconds at zero speed. This is called a Standstill ID run as

the motor will not turn. It is also called a MAG ID, or ID Run. Once all the motor data has been entered,

you will be prompted as follows:

Note – Although the motor may not appear to respond to the start command. There may be

an audible high-pitched sound coming from the motor which is normal.

Note – If the motor is repaired or replaced in the future, a Motor Identification run must be

performed again to maintain the accuracy of the PumpSmart drive.

The following procedure, while not spinning the motor, will energize

the motor. All safety precautions must be followed before initiating the

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

WARNING

1. Request to perform a Motor ID Run.

1. “Select”

2. Run the ID. 3. Wait

1. Push the “Green Start Button”

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Basic

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2. Perform a Motor Jog for Direction

Jogging the pump motor for correct rotation can be accomplished through the Motor Jog function.

The PumpSmart PS220 will rotate at 60 RPM and continue to do so until the rotation is confirmed to

be correct (or incorrect). If incorrect the drive will prompt you to correct the rotation and then ask you

to start it again to then confirm that rotation is correct. It will always only operate at 60RPM.

Note. There is no need to change any wiring on the (motor) load side of the PS220 to correct the rota-

tion. It is all done by an internal PumpSmart PS220 setting.

Never work on the PumpSmart PS220, 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 may result in serious injury or death.

DANGER

The Screen Shots below follow the sequence when the initial rotation is

incorrect. If it is correct the only screens 1, 2, 3, and 8 will apply.

1. 2. 3.

4. 5. 6.

7. 8.

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Basic

Startup

1.2. Basic Drive Setup Configuration Wizard

Refer the index in this manual for a more detailed description of the Functions that will

be configured with this Wizard. When this Wizard is completed, you will be able to run

the PS220 coupled to the motor in Basic Speed control mode.

This wizard will guide you, step by step as you progress, how to configure this function

for use. To access this Wizard, from the Home Screen follow the path: Menu>PS220

Configuration>Basic Startup>Basic Drive Setup

This functionality should only be configured with the PumpSmart PS220

Configuration Wizard.

Steps to be performed will be as follows:

1. Configure a Start and Stop source.

2. Configure the Min Speed.

3. Configure the Max Speed.

4. Confirm the operating mode for Speed

5. Configure a Setpoint Source

6. Exit the Wizard

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

progress, how to configure this functionality.

Starting the system in Speed control can be done after this configuration is

completed.

The PumpSmart PS220 drive uses specific motor details to create a mathematical model.

This model enables more accurate motor control and is created using the motor data

you have just entered. The PS220 will be magnetizing the motor from 20 to 60 seconds

at zero speed. This is called a Standstill ID run as the motor will not turn. It is also called

a MAG ID, or ID Run. Once all the motor data has been entered, you will be prompted

as follows:

The following procedure, while not spinning the motor, will energize

the motor. All safety precautions must be followed before initiating the

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

WARNING

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15 PS220

Basic

Startup

1. Request to perform a Motor ID Run.

1. “Select”

3. Wait

2. Run the ID.

1. Push the “Green Start Button”

Note. Although the motor may not appear to respond to the

start command. There may be an audible high-pitched sound

coming from the motor which is normal.

Note. If the motor is repaired or replaced in the future, a

Motor Identification run must be performed again to maintain

the accuracy of the PumpSmart drive.

DIIL Permissive

The PS220 will not run the motor unless

the Permissive input [DIIL] is closed

(24Vdc). This includes performing the

Motor ID Run. If not closed a warning

message will appear on the keypad

display:

The PS220 drive will come from the

factory with a jumper between the DIIL

input and 24Vdc. See Appendix A-4,

Instrument Wiring, for details on wiring

this switch.

Safe Torque Off

The PS220 will not run the motor unless

the Safe Torque Off (STO) is closed. The

Safe Torque Off inputs are typically used

for the external E-Stop circuit. If the

E-Stop is active (STO open) the keypad

will display:

The PS220 drive will come from the

factory with jumpers installed between

the STO Output and Inputs 1 and 2. If

an E-Stop push button is installed in

the STO circuit be sure the E-Stop is not

activated.

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