PumpSmart PS220 User manual

Configuration &
Operation Manual
PumpSmart®Control Solutions PS220 v6

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 an may eliminate un-
planned 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.ittproservices.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
Important Safety Reminder Page 03
PS220 Wizards Page 05
Basic Startup Page 07
SmartFlow Page 18
Process Control Page 34
Pump and VFD Page 43
protection
Multipump Page 64
Multivariable Page 68
Options and Features Page 72
Parameter Restore Page 159
Appendices Page 161
Keypad Use A-1 Page 161
Fault Tracing A-2 Page 167
Parameter Listing A-3 Page 178
Miscellaneous Page 199
Multipump connections Page 206
Basic Wiring & Installation A-4 Page 207
Quick Reference
• Wall mount units Page 211
• Floor mount units Page 213

PS220 Configuration & Operation Guide
3 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 4
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
5 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.
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
Parameter Restore
Keypad Use
Fault Tracing
Parameter List
Miscellaneous
Options & Features
Appendix

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

PS220 Configuration & Operation Guide
7 PS220
Basic
Startup
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 of the Pumpsmart function-
ality to properly perform. It MUST be performed prior to any other
functions/ features 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 Startup 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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PS220 8
Basic
Startup
Motor Parameter Configuration Wizard
The Pumpsmart PS220 will not operate unless the Electric Motor connected is
configured with all necessary information required.
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
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.
NOTE – The DIIL Permissive input cannot be
defeated through a parameter setting. If your
application does not use a Permissive switch
input, leave the factory jumper in place. Refer to
Appendix A-4, Instrument Wiring, for details.
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.
Fault Safe Torque Off - A5A0
Detail for the following Motor
Setup will come from the motor
nameplate. Be sure that if the
motor is a dual wound motor you
select the voltage and full load
amps for the motor as wired.

PS220 Configuration & Operation Guide
9 PS220
Basic
Startup
1. Configure the Motor Setup
1. Enter the mains Supply voltage 2. Configure the Motor Full Load Amps/
Current (FLA)
3. Configure the Motor Nominal Voltage 4. Enter the Motor Nominal Frequency
5. Configure the Motor full load RPM
(Slip Speed)
6. Configure the Motor nominal power
(HP or kW)