ITT PumpSmart PS220 Installation, Operation and Maintenance 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

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

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.

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

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

PS220 Configuration & Operation Guide

PS220 10

PS220 Configuration & Operation Guide

Basic

Startup

Motor ID

Motor Identification Run: PumpSmart 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 by magnetizing the motor for 20 to 60

seconds at zero speed. This is called a Standstill ID

run.

Once all the motor data has been entered, you

will see the following warning flash on top of the

screen:

This warning indicates that a Motor Identification

run is required before the pump may be operated.

Now is a good time to perform this run.

Note – Although the motor may not appear to

respond to the start command, it has. Alternatively,

you may hear an audible high pitched sound com-

ing from the driven equipment.

The following procedure will energize the motor. All safety precautions must be followed be-

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

A warning message, “ID run Active” will be displayed during the ID. Once the ID run is com-

plete, the message “ID DONE” will be displayed.

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

again to maintain the accuracy of the PumpSmart drive, with the new driven equipment.

Once this appears, proceed on to the next step, Motor Jog.

The following procedure

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

Select Start Wait

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

11 PS220

Jogging the Motor

Checking the motor for rotation can be accom-

plished through the Motor Jog function in which

the pump will rotate 60rpm until the operator af-

firms the direction of the motor, a stop command

is received, Fault, or Emergency Stop occurs.

Note – If pump rotation is incorrect then there

is NO NEED to change the output phases of the

drive. The drive can automatically do an internal

swap of the output power phases. Swapping two

of the input phases will not change the rotation of

the drive.

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

SelectWait

Start

Note – The jog function does not account for a Start delay, parameter

74.04 START DELAY must be 0 to perform the jog. The jog will only

follow the reference speed of 60rpm if the drive is set to have the Keypad

as the reference source, otherwise it will follow the minimum speed set in

parameter 30.11.

PS220 Configuration & Operation Guide

Level vs. Edge

The PS220 has multiple external Start/

Stop options that either requires con-

stant high input to the drive (level) or

a transition from either low to high or

high to low inputs (edge). for example,

HOA and 2 Wire are level type inputs,

where 3 wire is an edge type input.

See Appendix A-4, instrument Wiring,

for details on wiring Start/Stop Switches.

The drive will start if it is receiving a high start

input and it is in a Level Start/Stop mode after all

faults are cleared and interlocks are closed.

PS220 Configuration & Operation Guide

Basic

Startup

PS220 12

Basic Drive Setup

Basic Drive Setup outlines how to get the PS220 drive running in Speed Control,

with the option to setup Process Control when selecting the Operation Mode. Upon

completion of Basic Drive Setup, and as a result the completion of Basic Startup, the

user is strongly encouraged to go through other Wizards in the PS220 Configuration

Menu. Protecting your system, setting up Multipump systems and more all start

after completing this section.

Steps to be performed are:

1. Starting and Stopping Options

2. Selecting the Speed limits of the motor

3. Speed Control operation mode

a. Entering the Setpoint

b. Recommended Steps

c. Starting and Stopping the drive

4. Process Control operation mode

a. Continue to Process Control tabbed section

WARNING

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

13 PS220

Start/Stop

The PumpSmart PS220 has the ability to be remotely started and stopped from an exter-

nal source. Also, the PS220 can have the keypad included as a remote Starting and Stop-

ping location! If the PS220 will be operated without any external switches for starting

and stopping, then please proceed to the next step, keeping the default option “Keypad”.

Note – The PS220 has the ability to be controlled from two separate external commands.

Refer to Options and Features – Start/Stop Options.

Note – The following options only apply when the PS220 is in REMOTE mode, as indi-

cated in the top left corner of the keypad screen. When in LOCAL mode the Start/Stop

is controlled through the PS220 keypad exclusively. Refer to APPENDIX A-1 KEYPAD USE

for further details.

2 WIRE DI1 – This selection is used to start and stop the PS220 from a maintained

2-wire switch or contact wired to DI1 – Start/Stop.

3 W DI1P, 2P – This selection is used to start the PS220 from a normally open momen-

tary contact/switch wired to DI1 – Start, and stop the PS220 from a normally closed

momentary contact/switch wired to DI2 – Stop.

HOA DI1, 2 – This selection is used to start and stop the PS220 from a maintained

2-wire switch or contact wired to DI1 – AUTO. An additional contact can be wired to DI2

– Hand to initiate a Speed Override/Motor Jog function, in which the PS220 will operate

in a speed control mode. See Options and Features-Speed Override.

FIELDBUS – This selection is used to start and stop the PS220 from a Control Word sent

via a digital Fieldbus command. See Options and Features-Fieldbus Communication.

SaveEdit Scroll

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

PS220 14

Speed Range

The Speed Range defines the drive’s safe operating

limits. These limits safeguard the pump and drive

system from operating in unstable overspeed and/

or low-speed conditions.

Maximum Speed: The PumpSmart System will

adjust the speed of the motor to achieve the de-

sired operating setpoint. Although the PumpSmart

System can drive the motor at 2-3 times its

nameplate speed, this is generally impractical for

several reasons. First, unless the pump and motor

are designed for overspeed operation, they could

prematurely wear or even catastrophically fail.

Second, centrifugal pumps generate pressure by

the square of the speed and overspeed operation

may overpressure the pump or surrounding piping

system.

Enter the maximum speed that the pump, motor,

and system can operate at. In most cases the maxi-

mum speed will be the same as the previously entered full load RPM.

The default value is the speed set in parameter 99.09 Motor nominal speed.

MAX SPEED ≤ Full Load Motor RPM & Pump Max Speed

Assure that the system operating conditions

are within the capabilities (e.g. speed, pressure,

temperature, power, etc.) of the driven equip-

ment as rated by the manufacturer. Exceeding

any of these limits could result in failure of

components resulting in serious physical injury

and damage to equipment

WARNING

SaveEdit Next

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

15 PS220

Speed Range cont’d

Minimum Speed: As the demand on the pump decreases, PumpSmart will decrease the

pump speed to match the new demand. This Minimum Speed parameter sets the mini-

mum speed that the pump can operate at. It is also used to define the safe speed to run

the pump during a pump protection fault. The default value for minimum speed is 25%

of 99.09 Motor nominal speed.

When determining a minimum speed, consider the following:

1. Motor Minimum Speed [Turndown ratio]: Due to motor loading and thermal effects,

the motor minimum speed on centrifugal pumps should not be less than 1/10th its

full-load speed.

2. Pump Minimum Speed: Some pumps have minimum speed requirements, such as

multistage pumps (>2 stages) and sleeve bearing pumps. Consult your pump

operation manual to see if there is a minimum speed limit for your pump. Note: 1 &

2 stage pumps do not normally have minimum speed requirements.

3. Static Head Conditions (minimum flow): The minimum speed should be set to assure

that the pump generates enough head to overcome static resistance. In some cases,

this can cause overheating and possible vaporization of the liquid in the pump casing.

Enter the minimum speed that the pump and motor can safely operate at.

The default value is 25% of the speed set in parameter 99.09 Motor nominal speed.

Minimum Speed Sleep: The default settings will stop the pump if the process demand

requires the pump to operate below minimum speed. In the process control modes of

Pressure and Level control a SLEEP WARNING will be displayed in this case. The Sleep

Function will suspend the PS220 until process demand increases as defined by the RE-

START VALUE (parameter 75.06). Once the Restart Value has been achieved for longer

than the restart delay the pump will automatically restart to maintain the process set-

point.

Low Demand: In the flow control mode, control parameter 75.03 Sleep mode needs to

be changed to OFF. A PID LOW DEMAND fault will occur in which case the PS220 will

have to be manually reset. Alternatively, the drive may be set to operate at a minimum

speed until it is manually shutoff (parameter 79.16 Config Min Speed).

For a step by step procedure and more details please go to the Process Control tabbed

section and see Sleep Mode.

Operation below the pump safe minimum

speed could result in damage to equipment

and/or property.

Notice

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

PS220 16

Operating Mode

In this section, the operating mode of the PS220

is selected. Configuring the drive in either Speed

Control or Process Control is necessary to operate

the drive.

Speed Control Configuration: In this setup, the

drive is configured to operate the driven equip-

ment at a desired speed setpoint. A speed

setpoint can be input via the keypad, an external

analog signal, or Fieldbus. As an example an ex-

ternal PID Controller (DCS/PLC/etc.) can be used to

feed the PS220 with a reference speed signal.

Process Control Configuration: The PS220 is a

drive and Pump PID Controller all-in-one. The

Process Control Wizard needs to be completed

to operate the PS220 in a single pump (or Mul-

tipump) process control mode. In this mode, a

single pump is connected to your system with a

transmitter (pressure, level, flow, temperature, etc.)

wired to the PS220 to provide process

condition feedback. Alternatively, the drive features sensorless flow control with SmartFlow.

If the selection is Speed Control then the next page will ask the user to choose a setpoint

source. If the selection is instead Process Control, then a Pop-up window will ask the user to

please run the Process Control Wizard to configure the PS220.

PLEASE CONTINUE TO THE PROCESS CONTROL

SECTION IF YOU ARE OPERATING YOUR PUMP

IN PRESSURE, FLOW, LEVEL, SMARTFLOW, OR

TEMPERATURE CONTROL MODES.

OTHERWISE CONTINUE TO THE NEXT PAGE.

Important!

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

17 PS220

Setpoint (Speed Control)

In Speed Control, the desired running speed may

be selected in one of three ways:

1. Keypad [Default]

2. Speed Reference (via Analog input)

3. Fieldbus Control

The following details the use of a speed signal to

set the operating speed of the pump. This section

covers setting a speed reference locally at

the keypad or sending a speed reference via a

4-20mA signal wired to an Analog Input. For an

analog signal that is 2-10VDC, please see Options

and Features-Configuring the Analog Input Config-

uration.

Note – If you are using a Fieldbus reference please

refer to the Options and Features-Fieldbus.

Keypad: If you are using the Keypad for entry of

the running speed you can edit it on the Home Screen whenever you see the symbol next to

the reference. On the Home Screen the up and down arrow keys of the keypad will directly ad-

just your speed reference. Alternatively, under “Options” the reference can be adjusted quicker,

as seen below.

Note – To navigate back to the Home screen from anywhere in the drive Menus press the left

softkey as long as it is the Back/Exit option.

Note – There are several

alternate ways to enter a

speed setpoint. Refer to

the Options and Fea-

tures-Setpoints.

No EditOptions

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

PS220 18

Setpoint (Speed Control) cont’d

Speed Reference: For an analog speed signal, to

set the operating speed of the pump signal MAX

and MIN settings are required to properly scale the

signal. Either Analog Input 1 (AI1) or Analog Input

2 (AI2) can be chosen to receive an analog input

speed signal.

“AI1 scaled at AI1 min” is parameter 12.19 and

refers to the speed value that corresponds to the

minimum of the signal (4mA).

Example 1.2 – If you want your process to run at

800rpm when the 4-20mA speed signal is 4mA,

then you would enter “800” into parameter 12.19.

“AI1 scaled at AI1 max” is parameter 12.20 and

refers to the speed value that corresponds to the

maximum of the signal (20mA).

Example 1.3 – If you want your process to run at

3600rpm when the 4-20mA speed signal is 20 mA, then you would enter “3600” into parame-

ter 12.20.

When using a 4-20mA speed reference the Analog Input that the signal is wired to must be

defined in the drive. The Basic Startup wizard automatically defines the selected analog input

to “EXT SETPOINT 1” for the speed reference for the user.

Edit YesSave

PS220 Configuration & Operation GuidePS220 Configuration & Operation Guide

Basic

Startup

19 PS220

Recommended Step: Parameter Upload

Save your parameters in the Keypad. In the un-

likely event that the PS220 parameters are lost, the

Keypad can be used to restore the configuration.

It can also be used to program sister drive units

that use the same or similar program settings. For

more information refer to Options and Features-

Parameter Backups.

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ITT PumpSmart PS220 Installation, Operation and Maintenance Manual

ITT PumpSmart PS220 Installation, Operation and Maintenance Manual

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