Page 1 Configuration & Operation Manual PumpSmart Control Solutions PS220 v6.05 ®...
Page 2 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.
Page 3 PS220 Configuration & Operation Guide PumpSmart PS220 Wizards Page Number 1. Basic Startup 1. Edit Motor Parameters 2. Basic Drive Setup (Speed Control) 2. SmartFlow 1. Basic 2. Advanced 3. Smartflow Tune 3. Process Control 1. Process Control Mode 2. Sleep 3.
Page 4 PS220 Configuration & Operation Guide PumpSmart PS220 Wizards Page Number 8. I/O Configuration 1. Analog Inputs/Outputs 1. Analog 2. Analog Outputs 2. Digital Inputs/Outputs 3. Relays 9. Parameter Restore 10. Parameter Lock 11. Miscellaneous 1. Speed Override 2. SmartControl (PID Torque) 3.
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Page 6 PS220 Configuration & Operation Guide IMPORTANT SAFETY REMINDER 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.
Page 7 PS220 Configuration & Operation Guide With respect to PumpSmart drives and the operation of pumping equipment the following risks bear reinforcement above and beyond normal safety precautions: DANGER 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.
Page 8 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.
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Page 10 PS220 Configuration & Operation Guide 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.
Page 11 PS220 Configuration & Operation Guide 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>...
Page 12 PS220 Configuration & Operation Guide 1. Configure the Supply voltage 2. Configure the Motor Full Load Amps/Current (FLA) 1. “ARROW RIGHT” To change 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 2. “ARROWS” to change value 3. “Save” 3.
Page 13 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.
Page 14 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.
Page 15 Motor ID run. Failure to do so could result in serious injury or death. 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.
Page 16 PS220 Configuration & Operation Guide 1. Request to perform a Motor ID Run. 2. Run the ID. 1. “Select” 1. Push the “Green Start Button” 3. Wait 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.
Page 17 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.
Page 18 1. Configure the Start and Stop source. The PumpSmart PS220 drive will start and stop by using the Keypad as the default selection. The Green Button starts it and the Red button stops it. Other choices are available. Refer to the “Start/Stop”...
Page 19 PS220 Configuration & Operation Guide 3. Configure the Maximum Speed. The Maximum Speed by default is configure to the motor nameplate speed. Since pumps develop pressure at the square of the operating speed, and the Power consumed at the cube of the speed, caution should be taken to make sure that the maximum speed is within all limits of the pumping system to prevent damage that may occur.
Page 20 2. “ARROW UP/DOWN” To change. 3. “Select” 4. “Next” 2. Analog Input: An analog signal can be sent into the PumpSmart PS220, from a PLC, DCS or another form of controller. 1. “ARROW UP/DOWN” To change. 2. “Select” 3. “Next”...
Page 21 PS220 Configuration & Operation Guide 1. Scale the AI Minimum Speed 1. “ARROW RIGHT” to change 2. “ARROW UP/DOWN” To change. 3. “SAVE” 4. “ARROW DOWN” 2. Scale the AI Maximum Speed 1. “ARROW RIGHT” to change 2. “ARROW UP/DOWN” To change. 3.
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Page 23 2. The power value at shut off is at least 15% less than the power at BEP (Best Efficiency Point). 2. Advanced SmartFlow The PumpSmart PS220 can be utilized on pumps that do meet the criteria mentioned previously for Basic Smart Flow. It will require configuring Ad- vanced Smartflow.
Page 24 PS220 Configuration & Operation Guide 2.1. Configure Basic SmartFlow 1. Highlight “Basic Smartflow” 2. “Select” The next steps to be performed are: 1. Configure the Flow Unit 2. Configure the Pump Specific Properties 3. Configure Fluid Specific Gravity 4. Execute a Smartflow Tune 5.
Page 25 PS220 Configuration & Operation Guide 1. Configure the Pump Type 1. SS Centrifugal – Single Suction Centrifugal 2. DS Centrifugal – Double Suction Centrifugal 3. Mag Drive – Magnetic Drive Pump 4. PD Pump – Positive Displacement (Gear Pump) FUNCTIONALITY NOT AVAILABLE YET 1.
Page 26 PS220 Configuration & Operation Guide 4. Configure the BEP POWER value. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 5. Configure the SO POWER value. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3.
Page 27 1. Fluid Temperature measured with Transmitter: When changes to the SG are directly related to a change in the fluid’s temperature, the PumpSmart PS220 can monitor these changes using a temperature transmitter. This transmitter will need to be connected and configured to an available Analog Input.
Page 28 PS220 Configuration & Operation Guide 1. Configure Specific Gravity measurement with a Temperature Transmitter: 1.“Save” 1.“Next” 1. Configure fluid TEMP RATED. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 2. Configure fluid TEMP MIN. 1.
Page 29 PS220 Configuration & Operation Guide 5. Configure fluid SG Rated. 4. Configure fluid TEMP MAX. 1. “ARROW RIGHT” to change 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 2. “ARROWS” to change value 3. “Save” 3. “Save” 4. “ARROW DOWN” 4.
Page 30 2. Specific Gravity measured directly with a Transmitter: When Specific Gravity values vary linearly, and can be measured directly with a transmitter, the PumpSmart PS220 can monitor these changes using a Density transmitter. This transmitter will need to be connected and configured to an avail- able Analog Input.
Page 31 PS220 Configuration & Operation Guide 2. Configure the Identity of Analog Source of the AI to be used. 1. ”ARROW UP/DOWN” 2. “Select” 3. Configure the Min scaled value of the SG. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3.
Page 32 PS220 Configuration & Operation Guide 3. Two Rated Specific Gravities (Dual): Any available unused digital input can be configured to toggle between two predefined Specific Gravity values. SG 1 and SG 2. The steps you will need to perform are: 1.
Page 33 PS220 Configuration & Operation Guide 2.2. Advanced SmartFlow & Smart TDH Configuration Wizard Please refer to the Features & Functions section in this manual for a detailed explanation of this functionality. This Wizard will show the step-by-step in- structions to configure this functionality for use. To access this Wizard, from the Home Screen follow the path: Menu>PS220 Configuration>...
Page 34 PS220 Configuration & Operation Guide 3. Configure the Calculation Method 2. Total Dynamic Head 1. Brake Horsepower/ Total Dynamic Head Choice #1: BHP/TDH This choice will calculate the SmartFlow flow value using a combination of the BHP and TDH. This should be used if the power curve has “dips or bumps”.
Page 35 PS220 Configuration & Operation Guide 2. Configure the BEP TDH This is the Total Dynamic Head at the Best Efficiency Flow AND at the rated speed of the Pump. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3. “Save” 4.
Page 36 PS220 Configuration & Operation Guide 6. Configure the DELTA Z. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value The discharge pressure gauges height 3. “Save” above the centerline of the suction. 4. “ARROW DOWN” 5. Configure the Transmitter(s) and the associated Analog Inputs to be used for the TDH calculations.
Page 37 PS220 Configuration & Operation Guide 1. Scale AI2 Min Refer to 2. Scale AI2 Max Specific Refer to Analog Input Gravity. Configuration if necessary. Selection 2: Configure the use of a separate Discharge AND Suction Transmitter 1. Discharge Transmitter. 2. Suction Transmitter 1.
Page 38 PS220 Configuration & Operation Guide 2.3 SmartFlow Tune Wizard Please refer to the Features & Functions section in this manual for a detailed explanation of this functionality. This Wizard will show the step-by-step in- structions to configure this functionality for use. To access this Wizard, from the Home Screen follow the path: Menu>PS220 Configuration>Smartflow>...
Page 39 Personal injury may occur if the driven equipment is operated without coupling and shaft guards. WARNING Observe all CAUTIONS and WARNINGS highlighted in the ABB ACS880 Hardware Manual, and the PumpSmart PS220 Configuration Manual PS220 38 prior to starting.
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Page 41 PS220 Configuration & Operation Guide 3. Process Control Wizard This section will configure the PumpSmart PS220 to be used in single pump mode with the Process Control PID functionality. Scaled feedback will be required from wired analog transmitter(s)/sensors(s) connected the appropriate input(s).
Page 42 PS220 Configuration & Operation Guide 1. Configure the Process Control Operating Mode The PumpSmart PS220 will need to be configured to operate in a specific Process Control mode. Your choices are: Pressure: PumpSmart will maintain constant pressure to a setpoint.
Page 43 PS220 Configuration & Operation Guide 2. Configure the Unit Selection The configuration of the PumpSmart PS220’s unit selection will determine the labeling used to control the pump, the setpoint, and the actual feedback from the transmitter. Following are the available units based on your selection in 1 above.
Page 44 PS220 Configuration & Operation Guide 3. Configure the Transmitter Location The configuration of transmitter location on the PumpSmart SP220 identifies whether the transmitter is on the suction side of the piping system or on the discharge. 1. “ARROW UP/DOWN” to change 2.
Page 45 2. Differential pressure flowmeters [e.g., orifice plate, venturi, etc.] do not produce signals that are linear with flowrate. The PumpSmart PS220 cannot accommodate these types of flowmeters. 3. Refer to the transmitter manufacturer’s documentation for the proper wiring instruction and to determine the correct scaled values.
Page 46 PS220 Configuration & Operation Guide 4. The software automatically defines the selected analog input to “PROC TRANS 1” as the primary process transmitter for the system. 5. Configure the Setpoint limits. The setpoint limits, SETPOINT MIN and SETPOINT MAX, are the values, below and above, that the system cannot be operated at.
Page 47 2. “Select” 7. Configure the use of a Dual Setpoint (Optional) This optional selection will allow you to configure the PumpSmart PS220 to toggle between 2 separate setpoint references. Refer to the “Setpoint, Dual” section in this manual for more information. Configuring this option is not depicted here.
Page 48 This Wizard will show the step-by- step instructions to configure this functionality for use. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard, from the Home Screen follow the path: Menu>PS220 Configuration>Process Control>...
Page 49 PS220 Configuration & Operation Guide 1. Configure the sleep Mode. The choices are: 1. Off. Disable the Sleep function. 1. “ARROW RIGHT” to change 2. “ARROWS UP/DOWN” to change value 3. “Save” 2. Min Speed is the default setting. When set properly the drive will sleep as described above. With this choice the pump will sleep when the 3 values of “Sleep Value”, “Minimum Speed”, and the “Sleep Delay”...
Page 50 PS220 Configuration & Operation Guide 3. Configure the Restart Value 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 4. Configure the Sleep Delay 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3.
Page 51 PS220 Configuration & Operation Guide 3.3 PROCESS TUNE WIZARD (PI Tuning) The PumpSmart PS220’s PID tuning will allow you to fine tune the reaction of the pumping system to the process control setpoint. Depending on the Process control mode selected in the “Operating Mode”, defaults settings have been applied to simplify this fine tuning if needed.
Page 52 PS220 Configuration & Operation Guide 2. Configure the Decel Time. The default for this setting is 5 seconds. It can be adjusted as necessary. Range is from 0-1800 seconds. 1. “ARROW RIGHT” to change 2. “ARROWS” to change value 3. “Save” 4.
Page 53 Since the core functionality of the PumpSmart PS220 is that it is a Vari- able Frequency Drive (VFD), it also provides the ability to identify and react to the most common electrical system upsets such as Undervoltage, Overvoltage, Overcurrent, Stall, Underload and Overtemp.
Page 54 This event could be the result of several upset conditions both internal and external of the pump. The PumpSmart PS220 cannot determine what the cause of the event is but it will provide the desired notification and response if the event does occur.
Page 55 PS220 Configuration & Operation Guide Notes: 1. The PumpSmart PS220 keypad will display an alarm or fault message “Basic Pump Prot. Alarm” when this event occurs. 2. Basic Pump Protection is not available in Basic Speed Control. This functionality can be configured with the PumpSmart PS220 Configuration Wizard.
Page 56 PS220 Configuration & Operation Guide 2. Configure the Response 1. Disabled: The PumpSmart PS220 will not respond. The pump will continue to run at the maximum allowed speed and while not achieving the setpoint requirement. This is the Default. 2. WARNING: The PumpSmart PS220 will issue a warning message of “Basic Pump Protection”.
Page 57 5. Continue to 4.5 “Protection Options” on page 110. 4.2 Advanced Pump Protection Wizard The Advanced Pump Protection functionality uses the fully array of the PumpSmart PS220’s feedback from SmartFlow and Smart TDH in identifying upset conditions that may occur in the system.
Page 58 PS220 Configuration & Operation Guide 2. Configure the flow feedback source. There are two choices for this configuration: A. No (Default) this will utilize the values from Smartflow. B. Yes. This choice requires an external flowmeter. If it has not already been con- figured this Wizard will continue and guide you through the steps in adding it.
Page 59 3. Alarm & Control The PumpSmart PS220 will indicate that the pump is running at or below minimum with a mes- sage “Min Flow Warning”, after the response delay time has expired. The event will be stored in the Event Log.
Page 60 “Fault Tracing” in this manual. 3. Warning. The PumpSmart PS220 will continue to run and will indicate a message “Dry Run Warning” after the Response Delay time has expired. It will be stored in the event log. No other action will be taken.
Page 61 The PumpSmart PS220’s only available optional response is to provide a warning. The PumpSmart PS220 will continue to run. The warning message “RunOut” will display. The event will be stored in the Event Log. It will continue to indicate the warning until the flow decreases to a value below RunOut flow.
Page 62 PS220 Configuration & Operation Guide 1. “ARROW RIGHT” to change 2. “ARROW UP/DOWN” to change 3. “Save” 4. “Next” The following image illustrates both Minimum Flow and Runout Flow on a pump performance curve. Min Flow Runout Flow 7. Configure the Runout Flow Value. 1.
Page 63 This Wizard will show the step-by- step instructions to configure this functionality for use. This functionality can be configured with the PumpSmart PS220 Config- uration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Pump &...
Page 64 PS220 Configuration & Operation Guide 3. Configure the Digital Input to be used. 1. “Arrow Up/Down” to Define 2. “Select” 3. “Select” Notes: 1. It is recommended to use DI4 for Secondary Protection A and DI5 for Secondary Protection B 2.
Page 65 PS220 Configuration & Operation Guide 4.4 Condition Monitoring Wizard The PumpSmart PS220 can monitor two separate channels of informa- tion. This information can be from any of its analog transmitters connect- ed or from the onboard VFD and PUMP ACTUAL signals selected from specific parameter Groups.
Page 66 PS220 Configuration & Operation Guide NOTE: 1. When Selecting Proc. Trans 1, the Wizard will ask you to confirm all of the settings for its use. You will need to: 1. Confirm the AI it is wired to. 2.Confirm the Min. scaling, Max. Scaling, and the units 2.
Page 67 PS220 Configuration & Operation Guide 4. Configure the units for the Process Transmitter 2. 1. “Arrow Right” 2. “Arrow Up/Down” to change 3. “Save” 4. “Arrow Down” 2. Configure the Condition 1 Warning Limits High (and/or Low) Value: (If necessary) 1.
Page 68 You may have to change the configuration of Parameter 80.19 to allow the Response to the Monitoring of the values when the PumpSmart PS220 is either; “When Running”, or “Always”. The default is “Always” This change will need to be done manually by accessing that specific parameter directly.
Page 69 6. Configure the Min Speed Stop Delay time. When the monitored condition triggers a Warning or Alarm, the PumpSmart PS220 can be configured to run at its minimum speed for a timed duration. If the condition that triggered the warning has not cleared during this time, the drive will fault off and stop.
Page 70 PS220 Configuration & Operation Guide 7. Configure the Hysteresis Value. The Default is .20 of the units chosen for the condition. The range is 0-9999. 1. “Arrow Right” 2. “Arrows to Define” 3. “Save” 4. “Next” To Configure a Second Condition: Notes: For the configuration of the Second Condition only these steps would need to be followed.
Page 71 This Wizard will show the step-by-step instructions to configure this function- ality for use. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Pump &...
Page 72 PS220 Configuration & Operation Guide 4.5 VFD Protection Wizard The PumpSmart PS220 can be configured to protect itself from common electrical upset conditions, and to protect the motor from common electrical faults. By default, most all the selections are set to Fault.
Page 73 2. “ARROWS UP/DOWN” to change 3. “Save” 4. “ARROW DOWN” CAUTION This value should only be changed after consulting with an ITT Monitoring and Control Application Engineer, or ITT Commissioning Engineer. 3. Configure the Overvoltage control: The default is set to ON 1.
Page 74 PS220 Configuration & Operation Guide 5. Configure the Autoreset selection: The default for all each is Disabled. (Bit in BOLD is set to 0 = Disabled) 1. “ARROW RIGHT” To change 2. “ARROWS” right to change Bit value 3. “ARROW DOWN” to next Bit (repeat step 2) 3.
Page 75 PS220 Configuration & Operation Guide 8. Configure the Delay time: 1. “ARROW RIGHT” To change 2. “ARROWS UP/DOWN” to change value 3. “Save” 4. “NEXT” Note: If the “Number of trials” and the “Delay time” exceeds the ”Total trials time” the PS220 will not be able to reset automatically.
Page 76 Protection Options are covered in the section “VFD Auto-Reset”. 1. Configure the Protection Delay: The PumpSmart PS220 can be configured to delay the reaction time that The PS220 will wait until activating the control of any of the protection features.
Page 77 3. Configure the Pump Fault Reset: The PumpSmart PS220 can be configured to “Auto-Reset” up to a set number of times when the “Alarm & Control” choice has been configured for the “Protection Response“. The Default value is 0, which deactivates the function.
Page 78 5. Configure the Config Speed Min setting. The PumpSmart PS220 can be configured to run to a “Config Speed Min” speed choice when “Alarm and Control” has been configured as the Response for the Pump Protection selection. The choices are: 1.
Page 79 Functionality please refer to the sections that follow in this manual. This Wizard will show the step-by-step instructions to configure this function- ality for use. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Multipump...
Page 80 PS220 Configuration & Operation Guide 1. Configure the Multipump Mode. 1. “ARROW RIGHT” To change 2. “ARROW UP/DOWN” to change 3. “Save” 4. “NEXT” 2. Configure the Pump Address(S). 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4.
Page 81 PS220 Configuration & Operation Guide PS220 Configuration & Operation Guide 5. Configure the Stage and Destage Method The default value is SPEED or TORQUE 6. Configure the STAGE PROOF TIME: The default is 20 Seconds 1. “ARROW RIGHT” To change 1.
Page 82 PS220 Configuration & Operation Guide 9. Configure MAX PUMPS ON: 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “NEXT” 10. Configure the Stage/De-Stage Values for Pumps 2, 3 etc. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3.
Page 83 Analog Input. This wizard will completely configure this as you proceed. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Multivari- able>...
Page 84 PS220 Configuration & Operation Guide 1. Enable the Multivariable Control Functionality 1. “ARROW RIGHT” 1. “ARROW UP/DOWN” 1. “Next” 2. “Save” 2. Configure the source for the Secondary process transmitter 1. “ARROW RIGHT” To change 2. “ARROW UP/DOWN” to change value 3.
Page 85 PS220 Configuration & Operation Guide 4. Configure the Limits of Operation The limits of operation define the full interaction between the Analog Input you have selected in the previous step with the Primary Reference. Please refer to the example at the end of this section for assistance with the individual limit steps.
Page 86 PS220 Configuration & Operation Guide E. Configure the SPT HI 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” F. Configure the Hi INTRCPT 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3.
Page 87 PS220 Configuration & Operation Guide We suggest using diagrams like the one shown below: In the above diagram, the set-point is 50psi. When the secondary process transmitter (TX2) is below 5ft (LEVEL 1) of tank level, it will begin to scale back the set-point linearly from 50psig to 10psi (SP LO) at 2ft (LO INTRCPT).
Page 88 PS220 Configuration & Operation Guide 7. Water Functions Wizard The PS220 Water Functions will provide the functionality to alleviate common problems associated with pumping systems in the Municipal and Industrial marketplace. Many of the uses for these can l be found in the Waste Treat- ment, Water Treatment, and Water Distribution areas of these facilities.
Page 89 2. Opening Digital Input 3 (DI3), if it was used to start the PCS. Note: When either of these choices is used to stop the PCS the PumpSmart PS220 will need to be restarted. It will not restart on its own.
Page 90 PS220 Configuration & Operation Guide 1. Configure how the Pump Cleaning Sequence executes. (Manual or Automatic) 1. “ARROW RIGHT” To change 2. “ARROW UP/DOWN” to change value 3. “Save” 4. “ARROW DOWN” 2. Configure what triggers the Execution of the Pump Cleaning Sequence when PS220 is configure for step 1.
Page 91 PS220 Configuration & Operation Guide 4. Configure the proof time before executing the PCS once the request torque threshold is met. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 5. Configure the time of the day to execute the PCS. 1.
Page 92 PS220 Configuration & Operation Guide 8. Configure the forward speed run time during the PCS. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 9. Configure the forward run acceleration rate during the PCS. 1.
Page 93 PS220 Configuration & Operation Guide 12. Configure the reverse run speed during the PCS. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 13. Configure the reverse run time during the PCS. 1. “ARROW RIGHT” To change 2.
Page 94 PS220 Configuration & Operation Guide 16. Configure the maximum time the PCS is allowed to complete a full sequence. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 17. Configure the maximum number of complete sequences the PCS is allowed to run. 1.
Page 95 PS220 Configuration & Operation Guide 7.2 Snore Function Wizard The PumpSmart PS220’s Snore functionality primary use is to remove oil, grease, and other floating debris from the surface of the liquid in a vessel. This eliminates the need to schedule the vessel to have the level “pumped down”...
Page 96 PS220 Configuration & Operation Guide 2. Configure the Snore Torque Coefficient This value is used to terminate the Snore function. The Default value is 85% or .85. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “Next” 3.
Page 97 This Wizard will show the step-by-step instructions to configure the Pipe Clean Function for use. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home View, follow the path: Menu>PS220 Configura- tion>Water Function>Pipe Cleaning Function>l...
Page 98 PS220 Configuration & Operation Guide 2. Configure the Pipe Clean Time interval. This is the time interval used for step 1B. The default is 100 Hours. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3. “Save” 4. “ARROW DOWN” 3.
Page 99 This Wizard will show the step-by-step instructions to configure this functionality for use. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard, from the Home View follow the path: Menu>PS220 Configuration>Water Func- tions>Pipe Fill...
Page 100 PS220 Configuration & Operation Guide 2. Configure the Pipe Fill Time The fill time is the time frame that the PS220 will run the Pipe Fill function. The default value is 50 Seconds. 1. “ARROW RIGHT” To change 2. “ARROWS” to change value 3.
Page 101 PS220 Configuration & Operation Guide 8. I/O Configuration Wizard The PumpSmart PS220 utilizes 3 types of electric connections that can be in- dividually configured for use. This Wizard will guide you through configuring these connections The connection types are: 1. 1. Analog Inputs.
Page 102 PS220 Configuration & Operation Guide 8.1.1 Analog Input Configuration Wizard. To configure an Analog Input or Output, from the Home Screen follow the path: Menu>PS220 Configuration>I/O Con- figuration>No)>Analog I/O. 1. “No” 2. “Select” OR “Yes” if you are configuring the FIO-11optional Extension Module for the first time. If the Extension model is included, then wait until it loads software.
Page 103 PS220 Configuration & Operation Guide 1. Configure AI 1(if used). 1. “Arrow Down 1 time” (Bypass the line for AI tune) 2. Configure the Function/Name for AI1 Config. 1. “ARROW RIGHT” To change 2. “ARROW UP/DOWN” to select 3. “SAVE” 4.
Page 104 PS220 Configuration & Operation Guide 4. Configure the value in mA for the Min value. The default is 4mA 1. “ARROW RIGHT” To change 1. “ARROWS” to change 2. “SAVE” 3. “ARROW DOWN” 5. Configure the value in mA for the Max value. The default is 20mA. 1.
Page 105 PS220 Configuration & Operation Guide 7. Configure the Scaled Max value for the AI. This refers to the value that corresponds to the maximum of the signal for the 20mA scaled value. This is defaulted to 100. 1. “ARROW RIGHT” To change 1.
Page 106 PS220 Configuration & Operation Guide 8.1.2 Analog Output Configuration Wizard. To configure an Analog output from the Home Screen follow the path: Menu>PS220 Configuration>I/O Configuration>- No (or Yes if you are configuring the FIO-11optional Extension Module for the first time)>Analog I/O>Select>Next The steps that you will perform for each Analog Input: 1.
Page 107 PS220 Configuration & Operation Guide 3. Configure the Scaled Max value for the AO. 1. “ARROW RIGHT” To change 2. “ARROW UP/DOWN” to select 3. “SAVE” 4. “ARROW DOWN” 4. Configure the Min Value in mA for the AO Min value. 1.
Page 108 3. This PS220 Configuration Wizard CANNOT be used to change or modify the methods of starting and stopping, or to change or modify any of the Estop or Safe Torque Off functionality that is already in use on the PumpSmart PS220.
Page 109 PS220 Configuration & Operation Guide 2. Configure the Digital Inputs Function. There are 8 choices for the Function that this digital Input will be used for. They are all shown on the 3 screens below. 1. “ARROW UP/DOWN” to select 2.
Page 110 8.3 Relay Configuration Wizard The PumpSmart PS220 has 3 Form C “Dry Contact” relays on board as standard. They are fully configurable for different pumping system and electrical system operating conditions, to include warnings, and for fault conditions. Relays will revert to their original states once any warnings, faults, or the operating conditions that triggered them are reset or cleared.
Page 111 PS220 Configuration & Operation Guide 9. Restoring Factory Defaults Wizard The PumpSmart PS220 can be completely reset back to the original factory defaults. This will erase all the current settings that may have become cor- rupt, or you may be experiencing trouble during the normal operation of the system.
Page 112 PS220 Configuration & Operation Guide 3. Clear all Parameters. From the Home Screen follow the path: MENU>Parameters>Complete List> ARROW UP to “96 System”>Select> 1. “Arrow Down” to 96.06 2. “Edit” 3. “Arrow Down” to “Clear All” 4. “Save” 5. Wait 6.
Page 113 PS220 Configuration & Operation Guide 11. Miscellaneous Wizard This Wizard will configure the PumpSmart PS220 functionality for: 1. Speed Override. 2. Torque Control (SmartControl). 3. Advanced Pressure Control (System Curve Compensation). 11.1 Speed Override Wizard Please refer to the Features & Functions section in this manual for a detailed explanation of this functionality.
Page 114 PS220 Configuration & Operation Guide 1. Configure the method to activate the Speed Override function. There are 8 choices for the Function that this digital Input will be used for. They are all shown on the 3 screens below. 1. “ARROW RIGHT” To change 2.
Page 115 PS220 Configuration & Operation Guide 4. Configure the setting for Pump Protection when Speed Override is activated. 1. “ARROW RIGHT” to change 2. “ARROW UP/DOWN” to change value 3. “Save” 4. “Next” 5. Exit the Wizard. 1. Select “Yes” or “No” PS220 114...
Page 116 11.2 Torque Control (Smart Control) Wizard The PumpSmart PS220 has the functional capability to use the pumps torque rather than the pump speed in its PID Process Control Functionality. This allows for a significant improvement in the stable output of pump flow to maintain the process systems requirement.
Page 117 PS220 Configuration & Operation Guide 2. Configure the Torque Ramp up and Ramp down times to 5 Seconds. For Ramp up: 1. “ARROW RIGHT” To change 2. “ARROWS” to change value to 5 seconds 3. “Save” 4. “ARROW DOWN” For Ramp down: Repeat steps 1-4 1.
Page 118 PS220 Configuration & Operation Guide 11.3. Advanced Pressure Control Wizard Please refer to the Functions and Features section in this manual for a de- tailed explanation of this functionality. This Wizard will show the step-by-step instructions to configure this functionality for use. To access this Wizard, from the Home Screen follow the path: Menu>PS220 Configuration>Miscel- laneous Setup>Advanced Pressure Control The steps that you will perform:...
Page 119 PS220 Configuration & Operation Guide 3. Configure the Percentage Pressure Setpoint increase. 1. “ARROW RIGHT” To change 2. “ARROWS” to change 3. “SAVE” to continue. 4. “Next” 4. Exit the Wizard PS220 118...
Page 120: Table Of Contents
Functions and Features This section provides a detailed explanation off all the functionality provided on the PumpSmart PS220 as well as descriptions of common terms used with the functions. Each will provide a list with descriptions of all parameters used for the individual function to operate.
Page 121 PS220 Configuration & Operation Guide Priming Delay Protection Options Pump Protection Basic Pump Protection Advanced Pump Protection (Centrifugal) Positive Displacement Pump Protection Real Time Clock Reference/Setpoint Source Regulation Mode Relay Outputs Restoring Factory Defaults Runout/Runout Control Safe Torque Off Scalar Test Control Secondary Protection Shutoff Power Signal Supervision (Sensor Failure)
Page 122: Advanced Pressure Control
PS220 Configuration & Operation Guide Advanced Pressure Control (System Curve Compensation) The PumpSmart PS220 can be configured to automatically increase the systems operating pressure setpoint when an increase in the demand for more flow is required. This feature compensates for additional frictional losses associated with the higher flows and will set the new systems operating setpoint to a higher system matched value automatically.
Page 123: Alarm & Control
For Minimum Flow Protection: The PumpSmart PS220 will indicate that the pump is running at or below minimum flow with a message “Min Flow Warning”. After the response delay time has expired. The event will be stored in the Event Log. The PS220 will then re- spond based on the Protections Options.
Page 124: Analog Inputs
PS220 Configuration & Operation Guide Analog Inputs The PumpSmart PS220 has two configurable analog inputs as standard. By default, both inputs are current sourced and set to a scaled value of 4 to 20 mA. Each can be independently changed to a 0 to 10VDCvoltage sourced input by changing a jumper position on the control board.
Page 125: Analog Outputs
Analog Outputs The PumpSmart PS220 has two configurable analog outputs as standard. By default, both outputs are current sourced and set to a value of 0 to 20 mA. These outputs can be configured to any Signal in the Group 1 parameters. There is also a configurable choice for “Other”...
Page 126 1. The default value for both AO1 and AO2 Parameters 13.19 and 13.29 is 0 mA 2 The scaling on the receiving side needs to be identical to what is configured on the PumpSmart PS220 3. Refer to the wiring diagrams in the back of this manual for details on these connections.
Page 127: Auto Restart Functions
PS220 Configuration & Operation Guide Auto Restart The PS220 can be configured to automatically restart on conditions such as Power Failure, VFD faults, and Pump Protection faults. It can be set to reset a fault(s) up to a limited number of sequential attempts. If after these attempts the Fault condition did not clear or could not be reset the drive will produce a “Hard”...
Page 128: Pump Protection
PS220 Configuration & Operation Guide Auto Reset Pump Protection The PS220 can be configured to automatically reset a pre-defined pump related fault. If this condition occurs, the pump will ether go to its minimum speed, or fully stop for a limited duration. After this time frame it will automatically re-start. If the condition has cleared the pump will resume normal operation.
Page 129 After this time if the condition(s) still exists the PumpSmart PS220 drive will issue a “Hard” fault and will have to be manually restarted.
Page 130: Condition Monitoring
PS220 Configuration & Operation Guide Condition Monitoring The PumpSmart PS220 can monitor two separate channels of information. This information can be from any of its analog transmitters connected or from the onboard VFD and PUMP ACTUAL signals selected from specific parameter Groups.
Page 131 PS220 Configuration & Operation Guide 6. Configure the Min Speed Stop Delay time. The Default is 60 Seconds. The range is 0- 3600 seconds. 7. Configure the Hysteresis Value Hysteresis is the monitored difference (window) between the warning and alarm values, and the actual values used to deactivate a Condition event.
Page 132 PS220 Configuration & Operation Guide DESCRIPTION GROUP 80 CONDITION MONITORING A 1 indicates the condition is active 80.01 CONDITION STATUS FUNCTION DESCRIPTION Enabled Cond1 High Alarm Cond1 High Warning Cond1 Low Warning Cond1 Low Alarm Cond2 High Alarm Cond2 High Warning Cond2 Low Warning Cond 2 Low Alarm Sleep Active...
Page 133 PS220 Configuration & Operation Guide COND 2 WRN LIM LO The low value of the warning limit. A warning -10000 to +10000 80.12 occurs if the monitored signal drops below this value 0 [default] for longer than the response delay (par 80.16). Inactive if set to 0.
Page 134: Control Modes
Control Modes. (Process PID Control) The PumpSmart PS220 use can be configured to operate in a specific control mode using internal PID control functionality. This will allow a pumping system to maintain a stable rate of control to a defined setpoint, or reference.
Page 135 2. Configure the Control Modes Unit of Measure. The configuration of the PumpSmart PS220’s unit selection will determine the labeling used to control the pump, the set- point, and the actual feedback from the transmitter. Following are the available units based on your selection in 1 above.
Page 136 2. Differential pressure flowmeters [e.g. orifice plate, venturi, etc.] do not produce signals that are linear with flowrate. The PumpSmart PS220 cannot accommodate these types of flowmeters. 3. Refer to the transmitter manufacturer’s documentation for the proper wiring instructions, and to determine the correct scaled values needed for configuration.
Page 137: Critical Speed Lockouts
PS220 Configuration & Operation Guide Critical Speed Windows The PumpSmart PS220 can be configured to bypass operating speed windows to avoid resonance frequencies that may be encountered when running a pumping system. Refer to the pump manufacturer to determine if the pump being controlled has a critical speed within the defined operating speed range (between 30.11 MIN SPEED and 30.12 MAX SPEED).
Page 138 PS220 Configuration & Operation Guide Input L1 Input L2 Input L3 Red Probe on UDC+ terminal and black probe on the Input terminal Black Probe on UDC+ terminal and red probe on the Input terminals Red Probe on UDC- terminal and black probe on the Input terminal Black Probe on UDC-...
Page 139: Drive Composer
PS220 Configuration & Operation Guide Drive Composer Drive Composer is a free Windows based computer Tool that will allow you connect to the ITT PS220 PumpSmart through a connection on the Keypad that will all you to perform many tasks.
Page 140 PS220 Configuration & Operation Guide The next screen will automatically populate to show this: Select “File”, then “Print”: 139 PS220...
Page 141 PS220 Configuration & Operation Guide Select “OK” then wait: Change how you want them to print. Below is shown changing from the default printer to Microsoft Print to PDF: PS220 140...
Page 142 PS220 Configuration & Operation Guide Select “Print” Select the location where you want to save it to, (Folder, Desktop etc.), and then create the file name. Select “Save”. 141 PS220...
Page 143 PS220 Configuration & Operation Guide To close the application, Select “File”, then “Exit” Select “OK” PS220 142...
Page 144: Dead Head
3. A blockage or Clog in the discharge line preventing any flow from exiting the discharge end of the piping. When using the PumpSmart PS220’s PID Pressure or Smart THD Control Logic this can be completely avoided by performing the “Dead Head Test”...
Page 145: Digital Inputs
Digital Inputs The PumpSmart PS220 has 6 configurable Digital Inputs as standard. Each of these are normally closed and commonly sourced with an internal 24VDC supply. They can be inverted and forced on and off as required. There are 2 additional inputs that can be assigned as either an input or an output relay.
Page 146: Energy Savings Calculator
PS220 Configuration & Operation Guide Energy Savings Calculator The PumpSmart PS220 can calculate the energy savings as compared to a constant speed pump application. To enable this function to perform properly, local energy costs and comparative application information must be entered.
Page 147: Fault Functions Vfd
Fault Functions (VFD) The PumpSmart PS220 can be configured for various motor and variable speed drive hardware and electrical faults. By default, most all of these are set to Fault. See the VFD Auto-Reset section for details on, if and how, these may be able to be reset automatically.
Page 148: Fieldbus
Each of these will require an Adapter Module to be mounted and then configured for proper use. Please refer to the ABB IOM manual that is supplied with each of these Modules for detailed information on their operation and use. The Fieldbus Communications Protocols available with the PumpSmart PS220 are: Control Net...
Page 149 PS220 Configuration & Operation Guide Modbus Register Direction: Pointer in drive/PS220 Customer Setting Out from the PARAMATER PS220 40051 <- Status Word Status Word PS220 word 6.11 FIXED 40052` <- FBA ACT1 FBA ACT1 PS220 Word 40.01 Fixed 40053 <- FBA ACT2 FBA ACT2 PS220 Word TBD...
Page 150 PS220 Configuration & Operation Guide Please refer to the ITT PS220 Fieldbus Configuration Guides. PS220 Pump status “WORD 6.200” Bit Breakdown Remote Bit 0 M/F Ready Bit 1 Running Bit 2 Fault Bit 3 M/F Switch request Bit 4 Setpoint Changed...
Page 151 PS220 Configuration & Operation Guide 0 (0,0,0,0) to F 0 (0,0,0,0) to F 0 (0,0,0,0) to F 0 (0,0,0,0) to F (1,1,1,1) (1,1,1,1) (1,1,1,1) (1,1,1,1) DEC VALUE 3276 1638 8192 4096 2048 1024 512 BITS Stop Bits On 1150 Dec 1024 47E Hex 4 (0,1,0,0)
Page 152: Flow Totalizer
“Unlocked “by default with the choice of “No”. Language English American is the default language. On the PumpSmart PS220. Units of power are in HP. English (UK) notation refers to British English, with units of power in kW. The language selection between English (US) and English (UK) is configured in the Basic Startup Wizard upon first powering up of the drive.
Page 153: Local Control
PS220 keypad. This includes controlling both the start/stop function and the reference speed setting. Local control bypasses all PumpSmart PS220 control logic and functions except for ALL VFD PROTECTION which will remain intact. Refer to Keypad use for operation on how to switch from LOCAL to REMOTE control.
Page 154 C. Alarm & Control The PumpSmart PS220 will indicate that the pump is running at or below minimum with a message “Min Flow Warning”. After the response delay time has expired. The event will be stored in the Event Log. The PS220 will then respond based on the configured Protections Options.
Page 155: Minimum Flow Bypass
PS220 Configuration & Operation Guide Minimum Flow Bypass Recirculation The PS220’s Flow Bypass Recirculation function will allow for a triggered event that can be used to control the opening and closing of a minimum flow bypass valve that may be required in a pumping system. An available Relay Out can be used with this function to send the signals to external devices when required to operate.
Page 156: Motor Setup
PS220 Configuration & Operation Guide Motor Setup/Configuration 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 characteristics, execute a Motor ID, and verify correct motor rotation.
Page 157: Motor Id
PS220 Configuration & Operation Guide 2. Perform a Motor ID RUN 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.
Page 158: Motor Jog
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 rota- tion 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.
Page 159 PS220 Configuration & Operation Guide 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. PS220 158...
Page 160: Motor Rotation Check/Recheck
You can view the Motor Temperature in Parameter 35.01. If you wish to change the Motor Temperature Measuring method or how the protection is configured, please Contact your ITT PumpSmart Application Engineer, or Commissioning Engineer. 159 PS220...
Page 161: Transmitter Connections
PumpSmart Multipump Control Theory Overview. The PumpSmart PS220’s Multipump Functionality allows for the seamless automatic control of up to 6 pumps in a pumping system. Typically the pumps would be piped in parallel with each other. The staging and de-staging of each pump based on increases and decreases in demand has been pre-configured, as well as automatic lead-lag switching, and the automatic bypassing of a Pump/Drive combination that may experience faults of any kind.
Page 162: Minimum And Maximum Number Of Pumps
Minimum and Maximum number of pumps. The PumpSmart PS220 can be set up to operate a minimum number of pumps and also to limit the maximum number of pumps when required. The Maximum number of pumps is 6, the Minimum number of pumps is 1.
Page 163: Staging And Destaging
PS220 Configuration & Operation Guide Staging Pumps Basic Theory of Staging. The PS220 PumpSmart Multipump staging logic works based on 4 criteria: 1. A Pump is available with a Start Command Issued 2. The Process’s differential value between the setpoint and actual value. 3.
Page 164 PS220 Configuration & Operation Guide Staging Pumps Basic Theory of Destaging. The PS220 PumpSmart Multipump de-staging logic works based on 4 criteria: 1. Follower/Lag Pump is running 2. The Process’s differential value between the setpoint and actual value. 3. Pump Speeds 4.
Page 165 PS220 Configuration & Operation Guide Notes: 1. De-Staging values for up to 6 pumps are set to default values in the PS220 Multipump Functionality. For both Speed and Torque, these values are set to % of “Max Speed” (Parameter30.12). Recommendations for these values are as follows: Name Value...
Page 166: Lead-Lag Switching
PS220’s assigned address values. Basic Theory of Lead Lag Switching Alternation of the D2DMaster (Lead) to a D2D Follower (Lag) functionality on the PumpSmart PS220 in the Multi-pump control mode is accomplished in one the following ways: 1. Individual accrued pump runtime.
Page 167 PS220 Configuration & Operation Guide 2. Fault or Stop When the running D2D Master(Lead) is stopped manually or faults offline, the transfer of the D2D Master status will immediately switch to the next “Available” D2D Follower (Lag pump). It will always follow the sequence ring of 1-2-3-4-5-6 and not follow the accrued hours run time.
Page 168: Multipump Home Screens
PS220 Configuration & Operation Guide Multipump Home Screens The following screen shots document the detail of parameters that have been pre-configured to display on the keypad display when running the PS220 Multipump Control Function. M/F mode: The information displayed will either be “D2D master” or “D2D” follower. It will display “D2D master”...
Page 169: Multipump Wizard Menu Tree
PS220 Configuration & Operation Guide Multipump Menu Tree Below is the chronologic list of steps that the PumpSmart PS220 Multi- pump Wizard follow during the configuration of the system. The Section in the Wizards has each and every screen shot shown for easy step by step instructions.
Page 170 PS220 Configuration & Operation Guide 10. Configure the Stage/De-Stage Values for Pumps 2, 3 etc. The default values are as shown. Validate all during commissioning. Parameter Descrip�on Default Se�ng Stage 2 Value 81.09 Stage 3 Value 81.10 Stage 4 Value 81.11 Stage 5 Value 81.17...
Page 171: Pressure Boost
See the Diagram Below: The PumpSmart PS220 can optimize a constant pressure multi-pump system by adding a “boost pressure” to the pressure setpoint as pumps are staged on and subtracting it as pumps are staged off in these types of systems.
Page 172: Externally Powered Control Board
PS220 Configuration & Operation Guide Parameter Name Value/Range Notes 81.02 VALUE DECREASE 0-100% Defines the percentage difference decrease between the system set point versus the actual value to initiate 5% [default] staging of an available lag pump. Setting range = 0.0 – 100.0% of set point.
Page 173: Multipump Parameter Listing
PS220 Configuration & Operation Guide The table below lists all of the Parameters used in this function: DESCRIPTION GROUP 60 MULTIPUMP COMMUICATION SETUP Selects the node address of the drive for Multipump D2D Master and D2D Follower 60.02 PUMP ADDRESS communication.
Page 174: Multivariable Control
PS220 Configuration & Operation Guide Multivariable Control The PumpSmart PS220 Multivariable Control function will allow the Primary Process Controls Set- point to be varied, and or offset, with a second process transmitter signal. This functionality can be configured with the PumpSmart PS220 Configuration Wizard.
Page 175 PS220 Configuration & Operation Guide EXAMPLE – A pump configured for constant pressure draws from a tank. The level in the tank varies greatly, and occasionally drops enough that the pump begins to cavitate. The Basic Pump Protection on the PS220 would limit the speed of the pump or shut it off. Using the Multivariable Control feature would allow for pumping to continue, but at a reduced and allowable rate to prevent any harm to the pump, or the pumping system.
Page 176: Parameter Backup/Restore
PS220 Configuration & Operation Guide The table below lists all of the Parameters used in this function: Parameter Name Value/Range Notes 75.24 MULTIVAR CTL OFF [default] Set to “ON” to enable the Multivariable functionality 75.25 MULTIVAR REF SOURCE Analog Input 1 This parameter defines the source used in the Multivariable control function.
Page 177: Priming Delay
PS220 Configuration & Operation Guide To create a parameter Backup, follow these steps: 1. From the Home Screen: Menu> Backups> 2. Select create backup. If there is not a free backup slot in the control panel, skip to step 3. 3.
Page 178: Protection Options
3. Configure the Pump Fault Auto Reset: The PumpSmart PS220 can be configured to “Auto-Reset” up to a set number of times when the “Alarm & Control” choice has been configured for the “Protection Response” for any Pump Protection function.
Page 179: Pump Protection
1. The default is 60 seconds. The range is 0 - 3600 seconds. 5. Configure the Config Speed Min setting. The PumpSmart PS220 can be configured to run at either minimum speed or stop when “Alarm and Control” has been configured as the Response for the Pump Protection selection. The choices are: 1.
Page 180: Basic Pump Protection
This event could be the result of several upset conditions both internal and external of the pump. The PumpSmart PS220 cannot determine what the cause of the event is but it will provide the desired notification and response if the event does occur.
Page 181: Advanced Pump Protection (Centrifugal)
2. Advanced Pump Protection. The Advanced Pump Protection functionality uses the full array of the PumpSmart PS220’s feedback from SmartFlow and Smart TDH in identifying upset conditions that may occur in the system. This configuration will use these values of Dry Run, Minimum Flow and Runout Flow, along with the responses you estab- lish, to define the systems reaction to these events.
Page 182 C. Alarm & Control The PumpSmart PS220 will indicate that the pump is running at or below minimum flow with a message “Min Flow Warning”. After the response delay time has expired. The event will be stored in the Event Log. The PS220 will then re- spond based on the Protections Options.
Page 183 110-125% of the Best Efficiency Point Flow [BEP Flow]. The PumpSmart PS220’s only response when using the Advanced Protection is to provide a warning. This graphic depicts both the Minimum Flow and Runout Flow on a pump performance curve.
Page 184 ALARM AND CONTROL The PumpSmart PS220 will indicate that the pump is running at or below minimum flow with a message “Min Flow Warning”. After the response delay time has expired. The event will be stored in the Event Log.
Page 185: Positive Displacement Pump Protection
PS220 Configuration & Operation Guide Positive Displacement Pump Protection (PD and PC Pumps) Positive displacement and progressive cavity type pumps are significantly different from centrifugal pumps in that they maintain a constant torque load. The torque for this type of pump is a consistent value throughout all operating speeds. Typically the fluids pumped are used for lubrication of internal components.
Page 186: Real Time Clock
PS220 Configuration & Operation Guide Real Time Clock The PS220 has a built-in Real-time clock on Board. There are many ways that you can set and display this information. The time and date display settings determine how the time stamps are formatted to view on screen and in the event logs.
Page 187: Reference/Setpoint Source
PS220 Configuration & Operation Guide Reference/Setpoint Source The Reference or the Setpoint that PumpSmart PS220 will be maintaining will need to be configured. The keypad included is the default choice. An external source can be used that may require wiring with proper scaling values (minimum and maximum).
Page 188 NOTE: If you forget to set, or send a reference to the PumpSmart PS220, it will run at the minimum speed that had been configured in parameter 30.11. A warning message will not display if the reference is 0. In Process control mode it may run to maintain the reference but will not speed up higher than this value.
Page 189: Regulation Mode
PS220 Configuration & Operation Guide Setting/Adjusting the Reference: The reference can only be set and adjusted by the choice you have selected during configuration. If you chose the Keypad (default) you can use the Keypad for entry of the running speed. You can edit it on the Home Screen whenever you see the symbol to the left to the reference.
Page 190: Relay Outputs
PS220 Configuration & Operation Guide Relay Outputs The PumpSmart PS220 has 3 Form C “Dry Contact” relays on board as standard. They are fully assignable to oper- ating and fault conditions. Relays will revert to original states once warnings, faults and the operating conditions are reset or cleared.
Page 191: Restoring Factory Defaults
Restoring Factory Defaults The PumpSmart PS220 can be completely reset back to the original factory defaults. This will erase all the current settings that may have become corrupt, or you may be experiencing trouble during the normal operation of the system.
Page 192 PS220 Configuration & Operation Guide 1. “Arrow Down” to 96.06 2. “Edit” 3. “Arrow Down” to “Clear All” 4. “Save” 5. Wait 6. “Edit” 7. Arrow Up to “Restore defaults” 8. “Save” 9. Wait until home screen returns 10. Power cycle the PS220 11.
Page 193: Runout/Runout Control
The graphic depicts both Minimum Flow and Runout Flow on a typical pump performance curve. The Runout Control Function can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Pump & VFD Protection>Pump Protection>No>...
Page 194: Safe Torque Off
PS220 Configuration & Operation Guide Safe Torque Off Detection The PS220 is equipped with two on board Safe Torque off inputs that are located on the control board. Alternatively, the optional module FSO-12 or FSO-21 can be used if added protection is desired or if local electrical standards require an external module.
Page 195: Scalar Test Control
PS220 Configuration & Operation Guide Scalar Test/Control Scalar Test/Control Scalar control is a motor control method that does not rely on motor feedback when the standard ABB ACS880 drive is running. This control mode can only be used as a method to diagnose electrical faults as- sociated with the “Load-Side”...
Page 196 1. Should the drive fault off with the same message or messages as prior to running this test, the most likely problem is with the internal components of the drive. Contact your local ITT Gould’s Pumps Sales Engineer for further assistance.
Page 197: Secondary Protection
3. Alarm and Control The PumpSmart PS220 will indicate a “Secondary Protect A” warning message, after the response delay time has expired. The event will be stored in the Event Log. The PS220 will then respond based on the Protections Options.
Page 198 ALARM The PS220 generates a warning only “Secondary Protect A”. No further action is taken. The PumpSmart PS220 will indicate a “Secondary Protect A” warning message, 79.14 ALARM AND CONTROL after the response delay time has expired. The event will be stored in the Event Log.
Page 199: Shutoff Power
PS220 Configuration & Operation Guide Shutoff Power The PS220 has the ability to automatically calculate the power at “Shutoff” for the pump that will be used. This value is captured when the Smartflow Tuning Function is executed. This value is stored in Parameter 85.03 PSO 100%.
Page 200 PS220 Configuration & Operation Guide Selecting the choice of “NO Action” may result in running a pump up to full speed. If using the Multipump functionality it may run all of the additional pumps that have start commands initiated to try to regulate to the process setpoint. Parameter Name Value/Range...
Page 201: Setpoints Dual
PS220 Configuration & Operation Guide Setpoints - Dual The PumpSmart PS220 can be configured to use two separate and distinct setpoints, or references. The Set-point methods or references can be configured in the same fashion that are described in the Reference section.
Page 202 PS220 Configuration & Operation Guide For Speed Control: This procedure configures the PS220 keypad to set the speed reference for Setpoint 1 and for Setpoint 2. The steps required as follows: 1. Configure the PS220 for Basic Startup and end with Basic Drive Setup. From the Home screen view, follow the path: Menu>PS220 Configuration>Basic Startup>Basic Drive Setup>...
Page 203 PS220 Configuration & Operation Guide The table below shows that Digital Input 3 is defaulted to be used for the Dual Setpoint Function Parameter Name Value/Range Notes 76.11 DUAL STPT SEL This is the Default setting for this parameter. This selection will use setup digital input DI3 to toggle between set-point 1 and set-point 2.
Page 204: Sleep Function
PS220 Configuration & Operation Guide Sleep Sleep is a function that that can be configured on the PS220 that will allow the pump to automatically stop pumping while still completely satisfying the process control function assigned to it. This onboard logic will prevent pumping at “Deadhead”...
Page 205 PS220 Configuration & Operation Guide 3. Intelligent Sleep. This selection will utilize the pumps minimum flow value from an external flow meter, or from SmartFlow. With this choice the pump will Sleep when the values of “Sleep Value”, “Minimum Flow”, and the “Sleep Delay” have all been achieved. The PS220 will use internal logic to correctly determine the minimum flow as speeds change.
Page 206 PS220 Configuration & Operation Guide When all the condition are met for the “Sleep” function to activate the following message will display: NOTE: The MultiPump control functions will only allow the Master to Sleep. The table below lists all of the Parameters used in this function: GROUP 75 PROCESS CONTROL DESCRIPTION...
Page 207: Smartcontrol
“hunting”. The use of this functionality allows for the PumpSmart PS220 to be used with any system that traditionally could not be controlled with a “Flat Pump Curve” & “Flat System Curve”. This result of using torque is depicted in the graphic below.
Page 208 PS220 Configuration & Operation Guide The Smart Control functionality can only be configured with the PS220 Configuration Wizard. To access this Wizard from the Home View, follow the path: Menu>PS220 Configuration>Miscellaneous>Smart Control Parameter Settings The steps that you will follow to configure this functionality are as follows: 1.
Page 209 PS220 Configuration & Operation Guide TO “TURN OFF” Smart Control, reverting to Speed PID Control, you will follow the identical steps noted above and configure the settings as follows: 1. Configure the use of Speed for PID Process Control Configure both “EXT2 control mode” AND “EXT1 CONTROL MODE” to SPEED. 2.
Page 210: Smartflow Basic
Smartflow Basic SmartFlow The PumpSmart PS220 utilizes a complex algorithm that will calculate the actual flow of the pump. External sensors are not required with Basic SmartFlow. Any manufacturers pump will work with Smartflow. Basic SmartFlow is designed for low to medium specific speed pumps, under 3000NS. A pump with a specific speed under 3000 will have the following characteristics.
Page 211: Smartflow Advanced
PS220 Configuration & Operation Guide 1. To Configure Basic SmartFlow the following steps will be performed: 1. Configure the Flow Unit The SmartFlow unit selection identifies what units SmartFlow will display in. It also will be used for providing the necessary Pump Protection and input to other internal functions when required.
Page 212 For pumps that do not meet the criteria for Basic Smartflow the Advanced SmartFlow function configuration will be required. This will require added instrumentation to provide the necessary running feedback to the PumpSmart PS220 and additional pump and pumping system information. The configuration Wizard will guide you through this step by step.
Page 213 PS220 Configuration & Operation Guide To Configure Advanced SmartFlow the following steps will be performed: 1. Configure the Flow Unit (Same as Basic) 2. Configure the Pump Specific Properties (Same as Basic) 3. Configure the Calculation Method (Specific for Advanced) 4.
Page 214 PS220 Configuration & Operation Guide 1. Configure the PATM. This is the local barometric pressure at the location of the pump. (14.7 psi is normal) 2. Configure the BEP TDH This is the Total Dynamic Head at the Best Efficiency Flow, at the rated speed, of the Pump. 3.
Page 215 PS220 Configuration & Operation Guide 5. Configure the Transmitter(s) and the associated Analog Inputs to be used for the TDH calculations. A. For the Discharge Transmitter 1. Select the Analog Input that will be used. 2. Configure the Analog Input for use as Discharge pressure. If you have already configured a discharge transmitter with the Process Control Wizard, please select “PROC TTANS 1”...
Page 216 PS220 Configuration & Operation Guide The Table below lists all of the Parameters used for both Basic and Advanced Smart Flow. There are several parameters listed that are not used with the PS220 configuration Wizard functionality. They can be manually configured if required for a particular application. The description of these parameters are also listed in the index under Parameter Listings.
Page 217 PS220 Configuration & Operation Guide This is an example of a typical Pump Performance Curve. PS220 216...
Page 218: Smartflow Tune
PS220 Configuration & Operation Guide SMARTFLOW TUNE FUNCTION A SMARTFLOW tune function will calibrate the necessary information to compensate for mechanical losses, volumet- ric efficiency, casting defects, pump wear, eddy current losses, and general pump performance defects that can have an effect on the total pump efficiency that will not show up on a standard performance curve.
Page 219 PS220 Configuration & Operation Guide CAUTION Failure to follow the guidelines in this section can result in serious physical injury, death and/or equipment damage. Procedure for properly configuring and performing a SMARTFLOW TUNE with liquids with SG other than water (1.0 S.G.) at a customers’...
Page 220: Smart Tdh
Smart TDH PID Control The PumpSmart PS220 can regulate to the TDH of a pump using the information gathered when running the Advanced Smartflow Wizard. It will require the Control Mode configured using the Process Control Wizard to be set to Smart TDH.
Page 221: Specific Gravity/ Specific Gravity Correction
1. Fluid Temperature measured with Transmitter: When changes in the Specific Gravity are directly related to changes of the fluid’s temperature, the PumpSmart PS220 can monitor a temperature transmitter, and use values to update the calculated flow continuously. An unused Analog Input will be required.
Page 222 PS220 Configuration & Operation Guide 2. An unused AI will need to be used for either of these 2 choices to function correctly. Please check the settings of the Analog Inputs in use by going to: Menu>PARAMATERS> Complete List>Scroll down to Group 76>Select and View 76.01&02.
Page 223 PS220 Configuration & Operation Guide The table below lists all of the Parameters that may be used during the configuration of the Specific Gravity when using the Smartflow Wizard. The description of these parameters is also listed in the index under Parameter Listings. Parameter Name Value/Range...
Page 224: Speed Control
6. Exit the Wizard Speed Override The PumpSmart PS220 can be taken out of its primary control mode of operation and placed into complete MANUAL control. All the as configured control logic will be bypassed. The Speed Override function can be initiated through a wide range of choices. These choices are listed in the table below: Notes: 1.
Page 225 PS220 Configuration & Operation Guide This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard, from the Home Screen follow the path: Menu>PS220 Configuration>Miscellaneous>Speed Override Parameter settings. The Table below list all the Parameters used for the Speed Override Function. The description of these parameters are also listed in the index under Parameter Listings.
Page 226: Start Delay
1. Local Control Start/Stop When in LOCAL control the drive will run completely in manual mode and bypass all PumpSmart PS220 settings. It will run in manual speed control and can only be started and stopped with the Red and Green Buttons. The reference running speed can only be adjusted by the arrow up and down keys, or with the Options key.
Page 227 PS220 Configuration & Operation Guide ALL PS220 Features are designed to operate in REMOTE mode. 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. WARNING Observe all CAUTIONS and WARNINGS highlighted in the ACS880 Hardware Manual, PS220 Configuration and Operation Guide and Installation, Operation and Maintenance Guide for the...
Page 228 PS220 Configuration & Operation Guide 2: H-O-A DI1, 2 DI5 This is a commonly requested External Switch Combination used on the PS220 Refer to the diagram below. Functionality: “Auto Control” from two external locations. External Location 1: DI1 is assigned to “Auto” External Location 2: DI5 is assigned to “Auto”.
Page 229: Stop Function
COAST STOP Tuning The PumpSmart PS220 utilizes onboard PID control when running in any Process Control Mode. The two primary con- trolling functions are the Proportional Gain and the Integration time. The interaction of these properly configured settings allow for the running speed of the pump to quickly stabilize when the pump is turned on, and when there are gradual or rapid changes in the systems demand.
Page 230 Be sure all air is purged from the system before attempting tuning. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wizard from the Home Screen, follow the path: Menu>PS220 Configuration>Process Control>Process Tune 229 PS220...
Page 231: Underload (Freewheel)
PS220 Configuration & Operation Guide Underload (Freewheel) The PumpSmart PS220 can monitor the Motor load continuously and can be configured to react when the load suddenly drops. Typically, this is a result of a de-coupling between the motor and the pump.
Page 232 PS220 Configuration & Operation Guide 2. The settings for Parameters 37.11 through 15 should not have to be changed for a 1780 RPM motor. They will need to be change for motors of lower or higher full load synchronous speeds (1180 RPM and 3550 RPM).
Page 233: Vfd Protection
VFD PROTECTION Since the core functionality of the PumpSmart PS220 is that of a Variable Frequency Drive (VFD), it also provides the ability to configure the on-board electrical parameters to provide a very high degree of Drive and Motor protection. It will iden- tify and react to the most common electrical system upsets such as Undervoltage, Overvoltage, Overcurrent, Stall, Under- load and Overtemp.
Page 234 PS220 Configuration & Operation Guide The table below shows all of the parameters used for the VFD protection. Additional Motor limits and protection parameters are described in the index under the Parameter Listing for the Groups 30 and 31. GROUP 30 LIMITS DESCRIPTION 30.17...
Page 235: Water Functions
PS220 Configuration & Operation Guide Water Functions Pump Cleaning Function (PCS) The main function of the pump cleaning sequence (PCS) is to automatically detect and remove substances that may have become lodged in the pump or an inlet vane of the pump impeller. The PS220 can detect this during operation by moni- toring the actual motor torque value (1.10 MOTOR TORQUE).
Page 236 2. Opening Digital Input 3 (DI3), if it was used to start the PCS. Note: When either of these choices is used to stop the PCS the PumpSmart PS220 will need to be restarted. It will not restart on its own.
Page 237 PS220 Configuration & Operation Guide The test can be done as follows: 1. Switch to “LOCAL” Keypad Control. 2. Start the Pump by pressing the Green Start Button. 3. Set the Speed Reference to Max Speed and let the pump run to full speed. Check and validate that the pump is pumping with a “normal level”...
Page 238 PS220 Configuration & Operation Guide The table below lists all of the Parameters used in this function. Parameter Name Value/Range Notes 83.01 EXE P CLEAN SEQ Defines how the cleaning sequence is executed. NOT SEL (DEFAULT) The pump cleaning sequence is disabled. P CTRL DI3 The pump cleaning system is executed using DI3.
Page 239 PS220 Configuration & Operation Guide Parameter Name Value/Range Notes 83.01 EXE P CLEAN SEQ Defines how the cleaning sequence is executed. NOT SEL (DEFAULT) The pump cleaning sequence is disabled. P CTRL DI3 The pump cleaning system is executed using DI3. PS220 The pump cleaning system is executed by the PS220 automatically.
Page 240: Snore Function
PS220 Configuration & Operation Guide Snore Function The PumpSmart PS220’s Snore functionality primary use is to remove oil, grease, and other floating debris from the surface of the liquid in a vessel. This eliminates the need to schedule the vessel to have the level “pumped down”...
Page 241: Pipe Cleaning
When the Pipe Cleaning function is active the message “Pipe Clean Running” will be displayed on the Key- pad and will be captured and stored in the event log. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wiz- ard from the Home View, follow the path: Menu>PS220 Configuration>Water Function>Pipe Clean>l The individual steps that will be performed are: 1.
Page 242: Pipe Fill
When the Pipe Fill function is initiated, all PS220 functional control is disabled. It is automatically enabled once the function completes. This functionality can be configured with the PumpSmart PS220 Configuration Wizard. To access this Wiz- ard from the Home View, follow the path: Menu>PS220 Configuration>Water Functions>Pipe Fill Func- tion>l...
Page 243 PS220 Configuration & Operation Guide 3. Configure the Pipe Fill Speed The fill speed is the RPM value that the PS220 will ramp up to and remain at while the function is executing. The default value is 1000 RPM NOTES 1.
Page 244 PS220 Configuration & Operation Guide Keypad Use Installation Attach the control panel directly to the drive or use a separate mounting kit (cabinet door mounting). To attach the control panel: 1. Place its bottom end into the bottom of the slot in the drive (A), 2.
Page 245 PS220 Configuration & Operation Guide Display Control Location • Local – The drive is in local (speed) control and controlled from the keypad. • Remote – the drive is in remote control and start / stop is based on parameter 74.01. •...
Page 246 The main view of the control panel is called the Home view. In the Home view, you can view the current status of both Pump and VFD values. The PumpSmart PS220 Home View has 4 pages of 3 predefined lines of signal status as standard.
Page 247 PS220 Configuration & Operation Guide Parameter Access In the Parameters menu, you can access, view and edit parameters. In each sub-menu, you can edit a parameter by highlighting it and pressing “Edit”. Complete list In the Complete list sub-menu, all parameter groups are listed in numerical order. If you select a parameter group, all parameters in that group are listed.
Page 248 PS220 Configuration & Operation Guide Favorites In the Favorites sub-menu, only user-selected parameters are listed. The order is determined by the parameter number. Modified In the Modified sub-menu, only the parameters whose values differ from the defaults are listed. The order is determined by the parameter number. To Change the PS220 name that displays on the top-center of the keypad display.
Page 249 PS220 Configuration & Operation Guide PS220 FAULT TRACING The section lists most all of the PumpSmart PS220 Fault and Warning messages that may occur and display. It will describe in detail: 1. How to access the list of all current and historical events on the PS220 unit.
Page 250 PS220 Configuration & Operation Guide To access the Event Log from the Home View follow the Path: Menu>Event log>Select The last 32 fault and warnings are stored in the drives event logs. They are date and time stamped so they can be used for analysis.
Page 251 Please wait until the duration that was configured has expired before trying to reset and restart the PumpSmart PS220 again. It will need to be restarted in the same fashion as it was prior to any event(s) that may have caused the fault to occur.
Page 252 PS220 Configuration & Operation Guide • Open the suction valve. E205 PUMP PROTECT The actual process value is • Check suction line for blockages. lower than protection limit Warning Only • The Foot valve not opening on suction lift applications. •...
Page 253 PS220 Configuration & Operation Guide have been added to piping. • Check discharge piping static height compared to TDH output of the pump. E211 CONDITION 2 LO The signal level for Condition 2 • Investigate cause of condition WARNING • Check parameter settings of 80.12 fallen below the 80.
Page 254 PS220 Configuration & Operation Guide Table A2 - 2 All PS220 Pump and System Fault Messages Each message on the keypad displays the warning name as well as and unique code on the Keypad and store the event in the Event Log. CODE WARNING CAUSE...
Page 255 Try running the motor in scalar control mode if allowed. (See parameter 99.04 Motor control mode.) • If no earth fault can be detected, contact your local ITT representative. A2B4 Short circuit Short-circuit in motor cable(s) •...
Page 256 PS220 Configuration & Operation Guide Each warning message on the keypad displays the warning name as well as and unique code. The messages are listed in the ascending order of their fault codes. CODE WARNING CAUSE WHAT TO DO (HEX) A4A1 IGBT over temperature Estimated drive IGBT...
Page 257 PS220 Configuration & Operation Guide CODE WARNING CAUSE WHAT TO DO (HEX) A7C2 FBA B communication Cyclical communication • Check status of fieldbus communication. See user Programmable warning: between drive and fieldbus documentation of fieldbus interface. 50.32 FBA B Comm loss adapter module B or between •...
Page 258 Try running the motor in scalar control mode if allowed. (See parameter 99.04 Motor control mode.) • If no earth fault can be detected, contact your local ITT representative. 3130 Input phase loss Intermediate circuit DC voltage •...
Page 259 64A5 Licensing fault Running the control program • Record the auxiliary codes of all active licensing is prevented either because faults and contact your ITT representative for further a restrictive license exists, or instructions. because a required license is missing.
Page 260 PS220 Configuration & Operation Guide Each Fault message on the keypad displays the fault name as well as and unique code. The faults are listed in the ascending order of their fault codes. A fault will cause the drive the stop the pump. CODE WARNING CAUSE...
Page 261 PS220 Configuration & Operation Guide THIS PAGE IS INTENTIONALLY LEFT BLANK PS220 260...
Page 262 PS220 Configuration & Operation Guide PS220 Parameter Listing DESCRIPTION Scaling GROUP 1 ACTUAL VALUES See parameter 1.01 MOTOR SPEED Measured or estimated motor speed -30000 – 30000 RPM 46.01 1.02 MOTOR SPEED ESTIMATED Estimated motor speed in rpm. -30000 – 30000 RPM 1.03 MOTOR SPEED % Motor speed displayed as a percent of the synchronous speed.
Page 263 PS220 Configuration & Operation Guide Measured temperature of incoming cooling air. The amplitude range of 0…100% 1.70 AMBIENT TEMPERATURE % 1=1% corresponds to 0…60 °C or 32…140 °F. See also 01.31 Ambient temperature. -200.00- 200.00% Estimated motor current in A when a step-up transformer is in use. The value is calculated 1.71 STEP-UP MOTOR CURRENT from parameter 01.07 using the step-up transformer ratio (95.40) and sine filter values 99.18...
Page 264 PS220 Configuration & Operation Guide Reference 2 received from the external (DDCS) controller. The value has been scaled 3.12 DDCS CONTROLLER REF 2 1=10 according to parameter 60.60 DDCS controller ref1 type. (-30000.00-30000.00) Master/follower reference 1 received from the master. The value has been scaled according 3.13 M/F or D2D REF1 1-10...
Page 265 PS220 Configuration & Operation Guide ACS880-compatible fault word 2. The bit assignments of this word correspond to FAULT 4.22 FAULT WORD 2 WORD 1 in the ACS880. Parameter 04.120 Fault/Warning word compatibility determines whether the bit assignments are according to the ACS800 Standard or ACS800 System —...
Page 266 PS220 Configuration & Operation Guide GROUP 5 DIAGNOSTICS DESCRIPTION Scaling ON-TIME COUNTER On-time counter. The counter runs when the drive is powered. (0-65535 days) 5.01 1=1 day RUN-TIME COUNTER Motor run-time counter. The counter runs when the inverter modulates. (0-65535 days) 5.02 1=1 day FAN ON-TIME COUNTER...
Page 267 Defines the PS220 Hardware Example: ACS880-01-04A6-2 7.03 ABB ACS 880 FIRMWARE Defines the installed ABB Firmware Version. Example. 3.11.6.1 7.05 ITT APPLICATION Defines the ITT M&C Application Firmware running. 7.23 PUMPSAMRT VERSION Defines the PS220 installed Firmware version running. 7.30 DIGITAL INPUT AND RELAY...
Page 268 PS220 Configuration & Operation Guide 13.91-13.92 AO1 AND AO2 DATA STORAGE Reference the ABB ACS880 Firmware Manual for parameter definition. All ACS880 parameters may not be supported. I/O EXTENSION MODULE 1 DESCRIPTION GROUP 14 Refer to the ABB ACS880 Reference the ABB ACS880 Firmware Manual for parameter definition. All ACS880 parameters may not be 14.XX Firmware manual supported.
Page 269 PS220 Configuration & Operation Guide GROUP 30 LIMITS DESCRIPTION Defines the minimum allowed speed. 30.11 MINIMUM SPEED Defines the maximum allowed speed. 30.12 MAXIMUM SPEED Defines the maximum allowed motor current. Once this value is hit the motor will not go 30.17 MAXIMUM CURRENT higher in speed.
Page 270 Defines the Action taken when the Supervision Function 2 is activated: the choices are: No Action (Default); Warning; Fault; Fault if running. 32.17 SUPERVISION 2 SIGNAL Defines the signal used for the Supervision 2 function. There are 16 choices. ITT recommends using the Analog Inputs used. 32.18 SUPERVISION 2 FILTER Defines the time that the signal needs to be constant before activating the Supervision 2 function.
Page 271 PS220 Configuration & Operation Guide Reference the ABB ACS880 Firmware Manual for parameter definition. All ACS880 GROUP 41 – REFER TO THE ABB ACS880 parameters may not be supported with the PS220. FIRMWARE MANUAL DESCRIPTION GROUP 49 PANEL PORT COMMUNICATION Sets a timeout for control panel (or PC tool) communication.
Page 272 PS220 Configuration & Operation Guide Normally open EXT1: 2-Wire assigned to DI1. 2W DI1 - 2W DI5 EXT2: 2-Wire switch at DI5. This requires a preassigned switch (DI3) to switch between these choices. All switches are “normally open” FIELDBUS Start via Fieldbus control word. External control location 1 only. Control at two external locations.
Page 273 PS220 Configuration & Operation Guide DESCRIPTION GROUP 75 PROCESS CONTROL The time that the drive will run at full speed to prime. All functionality except for VFD 75.02 PRIMING DELAY protection is disabled during this time. The range is 0 – 6000 sec Defines the selections for SLEEP MODE.
Page 274 PS220 Configuration & Operation Guide Used for a Secondary External Setpoint for the Dual Setpoints functionality. EXT SETPOINT2 Used when Flow is used for the Control Mode or for use with Smartflow FLOWMETER Pump Protection Used with Advanced SmartFlow. DISCH PRESSURE Used with Advanced SmartFlow SUCTION PRESS Used with Advanced SmartFlow...
Page 275 PS220 Configuration & Operation Guide Defines the type of pump being used. PUMP TYPE Disables the SmartFlow function DISABLED Centrifugal type loads – use for single suction impellers 77.01 SS CENTRIFUGAL Centrifugal type loads – use for double suction impellers DS CENTRIFUGAL Centrifugal type loads with magnetic drive (eddy current) losses MAG DRIVE...
Page 276 The PS220 generates a “Min Flow Warning” only. ALARM AND CONTROL The PumpSmart PS220 will indicate that the pump is running at or below minimum flow with 79.08 a message “Min Flow Warning”, after the response delay time has expired. The event will be stored in the Event Log.
Page 277 The PS220 generates a warning only “Secondary Protect B”. No further action is taken. ALARM The PumpSmart PS220 will indicate a “Secondary Protect B” warning ALARM AND CONTROL message, after the response delay time has expired. The event will be stored in the Event Log.
Page 278 PS220 Configuration & Operation Guide COND 1 ALRM LIM HI The high value of the alarm limit. An alarm occurs if the 80.08 -10000 to +10000 monitored signal rises above this value for longer than 0 [default] the condition response delay (par 80.16). Inactive if set to 0.
Page 279 PS220 Configuration & Operation Guide GROUP 81 MULTIPUMP DESCRIPTION MODE Selects how multiple PS220 units operate together in parallel to satisfy the set-point. Multipump control is disabled. (Default) 81.01 Synchronous Speed. Lag pumps start as needed and all pumps regulate to the set-point at the same speed or torque.
Page 280 PS220 Configuration & Operation Guide Applicable only when 83.01 is set 83.02 REQ P CLEAN SEQ Defines what triggers the request of the pump to PS220. cleaning sequence. NOT SEL (DEFAULT) Disable the Automatic execution of the PCS TORQ The request is triggered when 1.10 MOTOR TORQUE exceeds the value set in 83.03 TORQ REQ for the 83.04 TON REQ.
Page 281 PS220 Configuration & Operation Guide 83.25 PIPE FILL TIME Maximum total time that the pipe fill function will execute. It will stop prior if a value is entered in 83.27 for Process PID control. 83.26 PIPE FILL SPEED Speed at which the pump will operate at during pipe fill. 83.27 PIPE FILL STOP VALUE Defines the actual value used in the primary PID control mode to stop the pipe fill function.
Page 282 PS220 Configuration & Operation Guide 99.06 MOTOR NOMINAL CURRENT Defines the nominal motor current. Must be equal to the value on the motor rating plate. If multiple motors are connected to the drive, enter the total current of the motors. Notes: •...
Page 283 PS220 Configuration & Operation Guide THIS PAGE IS INTENTIONALLY LEFT BLANK PS220 282...
Page 284 PS220 BASIC WIRING Instruments Loop Powered By PumpSmart PS220 Configuration & Operation Guide Multiple Transmitters/Jumpers JUMPERS NOTICE When PumpSmart is powering a 2-wire process transmitter, the current loop must be All instrumentation shielding must completed with a jumper from the PS220 analog input negative terminal to XD24-5. In be terminated at grounding lugs provided by the PS220.
Page 285 PS220 Configuration & Operation Guide Control Description connections Current input: 4(0) to 20 mA 2 differential analog External power input XPOW : 100 ohm inputs(XAI) Voltage input: 2(0) to 10 V "Green" +24VI External 24 VDC Power Input : 200 Kohm 24VDC 2A Maximum Resolution: 11 bit + sign bit Reference voltage and analog inputs...
Page 286 PS220 Configuration & Operation Guide Start / Stop Options - Single External Control Locations 2 Wire Start /Stop 3 Wire Start /Stop H-O-A [Momentary Push Buttons] "H-O-A" Terminal Block Terminal Block Terminal Block START STOP START STOP START (NO) AUTO AUTO - EXT 1 HAND HAND - SPEED OVERRIDE...
Page 287 PS220 Configuration & Operation Guide Potentiometer Option - Used to vary the Process Control Setpoint or a Speed Reference External power input XPOW +24VI External 24 VDC Power Input 24VDC 2A Maximum Reference voltage and analog inputs VREF(+) AI Reference Voltage 10VDC VREF(-) AI Reference Ground...
Page 288 PS220 Configuration & Operation Guide PS220 - Multi-Pump Connections RS-485 Connections between PS220 Drives 6 - Drive Arrangement (See Note 1) (See Note 1) Drive -1 Drive -2 Drive -6 3 - Drive Arrangement (See Note 1) (See Note 1) Drive -1 Drive -2 Drive -3...
Page 289 PS220 Configuration & Operation Guide Ecodesign Regulation PS220 288...
Page 290 PS220 Configuration & Operation Guide Commission Regulation EU 2019/1781, amendment (EU) 2021/341 sets new requirements for electric mo- tors and variable speed drives. The International Energy Agency works with countries around the world to shape energy policies for a se- cure and sustainable future.
Page 291 PS220 Configuration & Operation Guide 208-230 Vac ACS880-01-04A6-2 0.75 K03550A01 ACS880-01-06A6-2 K03550A02 ACS880-01-07A5-2 K03550A03 ACS880-01-10A6-2 10.6 K03550A04 ACS880-01-16A8-2 16.8 K03550A05 ACS880-01-24A3-2 24.3 K03550A06 ACS880-01-031A-2 K03550A07 ACS880-01-046A-2 K03550A08 ACS880-01-061A-2 K03550A09 ACS880-01-075A-2 18.5 K03550A10 ACS880-01-087A-2 K03550A11 ACS880-01-115A-2 K03550A12 ACS880-01-145A-2 K03550A13 ACS880-01-170A-2 K03550A14 ACS880-01-206A-2 K03550A15 ACS880-01-274A-2...
Page 292 PS220 Configuration & Operation Guide Fuses - heat dissipation chart 291 PS220...
Page 293 PS220 Configuration & Operation Guide HEAT HEAT AIR FLOW AIR FLOW ePrism RATED RECOMMENDED FUSE SIZE POWER (hp) DISSIPATION DISSIPATION ITT PART NO. CURRENT (A) /min) /hr.) (BTU/hr.) (Watts) NEMA 1 230 volt K03550A01 600V, 15A, Bussmann# JJS-15, Type T K03550A02...
Page 294 43620: HEAT HEAT AIR FLOW AIR FLOW ePrism RATED RECOMMENDED FUSE SIZE POWER (hp) DISSIPATION DISSIPATION ITT PART NO. CURRENT (A) /min) /hr.) (BTU/hr.) (Watts) 480 volt NEMA 1 K03552A01 600V, 10A, Bussmann# JJS-10, Type T K03552A02 600V, 15A, Bussmann# JJS-15, Type T...
Page 295 HEAT HEAT ePrism AIR FLOW AIR FLOW RATED RECOMMENDED FUSE SIZE POWER (hp) DISSIPATION DISSIPATION ITT PART NO. CURRENT (A) /min) /hr.) (BTU/hr.) (Watts) NEMA 1 525-690 volt 600V, 15A, Bussmann# JJS-15, Type T K03554A01 600V, 20A, Bussmann# JJS-20, Type T K03554A02 13.6...
Page 296 PS220 INSTALLATION QUICK REFERENCE - WALL MOUNT UNITS PS220 Configuration & Operation Guide ACS880-ITT01 NEMA 1 / NEMA 12 ACS880-ITT01 IP21 / IP55 Review the entire hardware manual prior t in serious personal injury, death and/or eq Free Space Required for Vantilation 7.9"...
Page 297 PS220 Configuration & Operation Guide WARNING Cable Entry Cable lead- Grounding L1,L2,L3,T1/U,T2/V,T3/W throughs terminals Review the entire hardware manual prior to Installation. Failure to follow these instructions may result in serious personal injury, death and/or equipment damage Frame Max. Ă* (Terminal Wire size T (Wire screw)
Page 298 PS220 INSTALLATION QUICK REFERENCE - FLOOR MOUNT UNITS PS220 Configuration & Operation Guide ACS880-07 IP22 / 42 and IP54 Front Above* Side 5.91 15.75 *measured from the base plate of the cabinet top. Note: 320 mm (12.28 in.) is required for fan Review the entire hardware ma replacement of IP54 cabinets.
Page 299 2 x 250 MCM 2 x (3x150) 2 x (3x240) ACS880-07-0414A-5 2 x 250 MCM **Disconnect / fusing provided by ITT on extended enclosure ACS880-07 2x400 MCM or 3x4/0 ACS880-07-0460A-5 3 x (3x95) 3 x (3x150) 1) Use a separate grounding PE cable (1a) or a cable with a seperate PE conductor (1b) if the...
Page 300 Visit our website for the latest version of this document and more information: http://www.ittproservices.com ITT Goulds Pumps Inc. 240 Fall Street Seneca Falls, NY 13148 ©2021 ITT Corporation Form IOM.PS220.en-US.2021-09 The original instruction is in English. All non-English instructions are translations of the original...

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