ITT PumpSmart PS220 User manual

Configuration &
Operation Manual
PumpSmart®Control Solutions PS220 v6.05

PS220 Configuration & Operation Guide
1 PS220
Getting
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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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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
5 PS220
Getting
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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.