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PS200 Programming & Operation Guide

APPENDIX A-5 QUICK REFERENCE INSTALLATION DRAWINGS

Page 147

Fiber-Optic Connections between PS200 Controllers

SYNCHRONOUS MULTI-CONTROLLER AND BACKUP MODES ONLY

Constant Speed Slave Pump Wiring

ONE PUMPSMART UNIT WITH UP TO THREE CONSTANT SPEED PUMPS/STARTERS

PS200 - ACS800 Multi-Pump Connections

2-Drive Arrangement

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

Drive 1

(MASTER)

Drive 2

3-Drive Arrangement

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

Drive 1

(MASTER)

Drive 2

Drive 3

4-Drive Arrangement

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

CH-2

Multi-Pump

(MSTR-FOLL)

RDCO-03 Module

Partial View

CH-1

(I/O)

CH-3

(PC-Connect)

Drive 1

(MASTER)

Drive 2

Drive 3

Drive 4

Fiber Optic Cables

-Light colored connector to light

colored receptical.
-Dark colored connector to dark

colored receptical

-MINIMUM BEND RADIUS: 2 Inches

Extra cable may be looped and stored

within the drive. Maintain minimum

bend radius.

Fiber optic cable ends are not the same

color.

Fiber Optic Cable Kit

Part Numbers

2 Pumps - 800MP2

3 Pumps - 800MP3

4 Pumps - 800MP4

The RDCO-03 DDCS

COMMUNICATION

MODULE is to be mounted

in the DDCS slot and affixed

with (2) screws provided

RO1 (X25) Slave 1
RO2 (X26) Slave 2
RO3 (X27) Slave 3

Relay Output Specifications

Switching Capacity

8A at 24 VDC or 250 VAC

0.4A at 120 VDC

Maximum Continuous Current:

2 A RMS

START/STOP

By Customer

Control Loop

Power Source

ON/OFF

E-Stop

PS200 Form C Relays

SLAVE MOTOR

STARTER

Slave Motor

Power

Supply

1 RO NC

2 RO COM

3 RO NO

ASSIGNABLE RELAY OUTPUT

PARAMETERS 19.01, 19.04,
AND/OR 19.07 SET TO "START
SLAVE"

B05027A

SHEET 1 OF 1

REV

Issue

PS 200 ACS 800 Multipump

Connections V4.0

Drawing is not to scale

Dimensions in inches [mm]

Checked: Tony Stavale

Drawn: AI 060204

PS200

X21

X22

X23

X25

X26

X27

X20

!! NOTE !!

PumpSmart issues run commands to constant speed slave units via relay output run (2-wire

start/stop).

Control loop must be powered (e.g. 24 VDC or 120 VAC.

The default starting order for multiple constant speed slave units is:

RO1 - Starts/stops first constant speed slave pump. Destages pump using the 22.07

SYNC LIMIT.

RO2 - Starts/stops the second constant speed slave pump. Destages this pump using

22.07 SYNC LIMIT and 22.08 SYNC WINDOW

RO3 - Starts/stops the third constant speed slave pump. Destages this pump using

22.07 SYNC LIMIT and 2x 22.08 SYNC WINDOW

Summary of Contents for PumpSmart PS200

Page 1: ... PUMPSMART CONTROL SOLUTIONS PS200 Version 4 0 Configuration Operation Guide ...

Page 2: ......

Page 3: ...rocess Configuration Section 2A Multi Pump Process Configuration Section 2B Single Pump Speed Control Configuration Section 2C Options Features Section 3 Appendices Keypad Use A 1 Fault Tracing A 2 Parameter Listing A 3 Basic Instrument Wiring A 4 Quick Reference A 5 Installation Drawings ...

Page 4: ......

Page 5: ...le 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 set point 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 Entering motor data f...

Page 6: ...nter parameter setting mode OR Use the double arrow keys to scroll through Parameter Groups OR Use the single arrow keys to scroll through Parameters in each group ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll through selections or enter values Double arrow keys are used for fast scrolling while single arrow keys are for slow scrolling ENTER Pr...

Page 7: ...ive has been mounted properly Refer to the hardware manual for installation details x Power has been properly wired to the drive and from the drive to the motor x Process transmitter s and optional appurtenances have been installed and correctly wired If these steps have not been completed please stop and complete them before proceeding Once these steps are completed select the configuration secti...

Page 8: ......

Page 9: ... Pump Overview 1 Locks Passwords 10 02 2 Motor Setup Drive data for the First Motor Run ID is entered here in addition to start stop methods and MAX and MIN drive speeds 12 01 11 04 11 05 11 07 11 08 14 01 14 02 3 Operating Mode Units Selects the mode of operation and the primary process transmitter setup 11 03 15 01 16 03 16 04 4 Setpoint Pump Protection Limit 25 01 25 02 Start Stop CHECK GO STEP...

Page 10: ...SWORDS OR Scroll to parameter 10 02 PASS CODE ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the number 358 To open the Parameter lock scroll to parameter 10 02 and enter the passcode 358 The display value will automatically return to 0 after the three digit code has been entered To check on the status of the parameter lock scroll to paramete...

Page 11: ...itch or when an manual override switch is desired Three wire pulse start pulse stop Fieldbus control PumpSmart may be remotely started through a DCS system This option does require the optional Fieldbus communication module Refer to the FIELDBUS CONTROL option for further details 12 01 START STOP KEY SEQUENCE From parameter group 10 LOCKS PASSWORDS OR Scroll to parameter group 12 START STOP Parame...

Page 12: ...se a combination of the arrow keys to scroll to the nameplate motor voltage Enter the value for motor voltage and frequency as found on the motor nameplate Available selections are 208 VAC 60HZ 220 VAC 50 Hz 220 VAC 60 Hz 230 VAC 60 Hz 380 VAC 50 Hz 415 VAC 50 Hz 460 VAC 60 Hz default 575 VAC 60 Hz OTHER Selecting OTHER will require entry in parameters 11 06 MOTOR NOM FREQ and 11 12 OTHER MOTOR VO...

Page 13: ...l load RPM of 1770 RPM ENTER Press to complete the entry 11 08 MOTOR NOM POWER KEY SEQUENCE From parameter 11 07 MOTOR FL RPM OR Scroll to parameter 11 08 MOTOR NOM POWER ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the nameplate power Enter the nominal power HP or kW of the motor as found on the motor nameplate If you are using the Default...

Page 14: ...RE STOPPING RESETTING THE DRIVE Although the motor may not appear to respond to the start command it has A warning message ID MAGN will be displayed during the ID Once the ID run is complete the message ID DONE will be displayed NOTE If the motor is changed in the future a First Start ID Run must be performed again to maintain the accuracy of the PumpSmart control Once the First Start ID Run has b...

Page 15: ...ter group14 SPD LIM STRT LVL Parameter 14 01 will be the first selection ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the maximum speed Enter the maximum speed that the pump motor and system can operate at In most cases the maximum speed will be the same as the previously entered full load RPM MAX SPEED d Full Load Motor RPM and d Pump maxi...

Page 16: ...n safely operate at Consider x Turndown ratio x Pump minimum speed x Minimum flow The default value is 25 of the speed set in parameter 11 07 MOTOR FL RPM ENTER Press to complete the entry NOTES The default settings of the PumpSmart drive will stop the pump if the process demand requires the pump to operate below the minimum speed A LOW DEMAND Fault will be displayed in this case A delay can be se...

Page 17: ...also be used PumpSmart can control the level in either a suction or discharge tank x Temperature OTHER used to maintain defined temperature of a process stream based on a temperature transmitter signal Also use this selection if a 4 20 ma signal from a different type of transmitter is used 11 03 MODE SELECT KEY SEQUENCE From parameter group 14 02 MINIMUM SPEED OR Scroll to parameter group 11 START...

Page 18: ...ss variable 15 01 AI2 UNIT KEY SEQUENCE From parameter group 11 03 MODE SELECT OR Scroll to parameter group 15 PROCESS VAR UNIT Parameter 15 01 will be the first selection Select the proper units of the operating mode Skip to the next step if the default unit is okay otherwise select ENTER Press to enter the parameter setting mode OR Scroll to the appropriate measurement units Example shown is PSI...

Page 19: ...set to 2000 in this case The units of 16 03 are the same as selected in parameter 15 01 NOTES Differential pressure flowmeters e g orifice plate venturi do not produce 4 20 mA signals that are linear with the flow rate PumpSmart refers to this as a QUADRATIC input Refer to the section DIFFERENTIAL PRESSURE FLOWMETERS in the options section for proper setup 16 03 AI2 MAX KEY SEQUENCE From parameter...

Page 20: ...p may be omitted since the default of parameter 16 04 is 0 16 04 AI2 MIN KEY SEQUENCE From parameter group 16 03 AI2 MAX OR Scroll to parameter 16 04 AI2 MIN ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the correct value Example shown 0 PSIG Enter the reading of the primary process transmitter that corresponds to its 4 mA signal If your tra...

Page 21: ...mart unit from a remote location Variable Setpoint A second process transmitter 2 10VDC or 4 20 mA may be used to vary the setpoint The setpoint can be linear inverse linear or offset to this signal See OPTIONS FEATURES for details Multiple setpoint The PumpSmart system can be programmed with two setpoints and the drive can toggle between the two setpoints based upon a digital switch e g flow swit...

Page 22: ...t in damage to the pump if a protection limit fault occurs and no manual intervention is taken 3 DISABLED Default Setting In this response there is no protection limit functionality If a closed suction valve or similar condition exists there may be damage to the pump and there will be no alarm warning the user 25 01 PUMP PROTECT CTRL KEY SEQUENCE OR Scroll to parameter 25 01 PUMP PROTECT CTRL ENTE...

Page 23: ...otection warning fault would occur if the pump was at maximum speed and flow fell below 60 GPM 25 02 PROTECTION LIMIT KEY SEQUENCE From parameter 25 01 PUMP PROTECT CTRL PAR Press PAR button to enter to the Actual Signal screen OR Press the double arrow key to go to parameter group 25 PUMP PROTECT OR Press the single arrow key to go to parameter 25 02 PROTECTION LIMIT ENTER Press to enter the para...

Page 24: ...e PS200 parameters are lost the keypad can be used to restore the configuration It can also be used to program sister units that use the same or similar program settings Recommended Option Drive Locking See OPTIONS FEATURES The keypad can locked to prevent unauthorized personnel from making operational changes or changes to the parameter groups See LOCKING in OPTIONS FEATURES ...

Page 25: ... scroll to parameter 12 09 MOTOR JOG and selecting JOG Once selected PumpSmart will turn the motor at 60 RPM for 10 seconds If rotation is reversed the position of two leads must be changed either at the drive output U2 V2 W2 or at the motor T1 T2 T3 Refer to the Quick Reference Installation drawings in the appendix E Stop Permissive The PS200 will not operate unless the E Stop Permissive switch D...

Page 26: ......

Page 27: ...ntered here in addition to start stop methods and MAX and MIN drive speeds 12 01 11 04 11 05 11 07 11 08 14 01 14 02 3a Operating Mode Units Selects the mode of operation and the primary process transmitter setup 11 03 15 01 16 03 16 04 3b Multi pump Settings Selects how the multiple pumps will work together to satisfy the system demand 22 01 22 02 22 03 22 04 22 07 22 08 22 13 4 Setpoint Pump Pro...

Page 28: ...ill start a second PS200 pump The lead PS200 will continue at maximum speed while the lagging drive will regulate speed to meet the setpoint If demand is still not met the lead drive will start a third and if required a fourth pump to meet the demand In each case the last PS200 drive pump started will regulate to the setpoint When demand drops PumpSmart will de stage pumps that are no longer requi...

Page 29: ...d pump and the constant speed pump is always the lag pump NOTE It is possible to use dissimilar pumps in any of the above Multi Pump modes Caution should be exercised however to ensure that pump head curves are similar to prevent operation at shut off or check valve chatter on the lower head pump s IT IS RECOMMENDED THAT ALL PUMPS BE IDENTICAL IN PERFORMANCE 1 2 Discharge Header F Standard starter...

Page 30: ...e set to AUTO or pulse start and the keypad set in REMOTE Discharge Header P 1 2 P P Pressure Transmitter Flow Switch RUN STOP AUTO OFF 1 DI1 2 DI2 3 DI3 4 DI4 5 DI5 6 DI6 7 24 VDC 8 24 VDC 9 GROUND DIGITAL SWITCH POWER SOURCE OPTI ON DIGITAL SWITCH POWER SOURCE OPTI ON DIGITAL SWITCH GROUND OPTI ON START START STOP WIRING 2 Wire configuration DUAL TWO SETPOINT SELECTION SECONDARY PUMP PROTECTION ...

Page 31: ...ODE ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the number 358 To open the Parameter lock scroll to parameter 10 02 and enter the passcode 358 The display value will automatically return to 0 after the three digit code has been entered To check on the status of the parameter lock scroll to parameter 10 01 After correctly entering the passc...

Page 32: ... 11 02 APPLICATION MACRO KEY SEQUENCE From parameter group 10 02 LOCKS PASSWORDS OR Scroll to parameter group 11 START UP DATA OR Scroll to parameter 11 02 APPLICATION MACRO ENTER Press to enter the parameter setting mode OR Scroll to the MULTI PUMP selection Select the multi pump application macro ENTER Press to complete the entry ACT PAR FUNC DRIVE ENTER 1 L Æ 0 PSIG 0 11 START UP DATA 2 APPLICA...

Page 33: ...ulse stop Fieldbus control PumpSmart may be remotely started through a DCS system This option does require the optional Fieldbus communication module Refer to the FIELDBUS CONTROL option for further details 12 01 START STOP KEY SEQUENCE From parameter 11 02 APPLICATION MACRO OR Scroll to parameter group 12 START STOP Parameter 12 01 will be the first selection ENTER Press to enter the parameter se...

Page 34: ... setting mode OR OR Use a combination of the arrow keys to scroll to the nameplate motor voltage Enter the value for motor voltage and frequency Available selections are 208 VAC 60 Hz 220 VAC 50 Hz 220 VAC 60 Hz 230 VAC 60 Hz 380 VAC 50 Hz 415 VAC 50 Hz 460 VAC 60 Hz default 575 VAC 60 Hz OTHER Selecting OTHER will require entry in parameters 11 06 MOTOR NOM FREQ and 11 12 OTHER MOTOR VOLT ENTER P...

Page 35: ... a full load RPM of 1770 RPM ENTER Press to complete the entry 11 08 MOTOR NOM POWER KEY SEQUENCE From parameter 11 07 MOTOR FL RPM OR Scroll to parameter 11 08 MOTOR NOM POWER ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the nameplate power Enter the nominal power HP or kW of the motor as found on the motor nameplate If you are using the D...

Page 36: ...TE BEFORE STOPPING RESETTING THE DRIVE Although the motor may not appear to respond to the start command it has A warning message ID MAGN will be displayed during the ID Once the ID run is complete the message ID DONE will be displayed NOTE If the motor is changed in the future a First Start ID Run must be performed again to maintain the accuracy of the PumpSmart control Once the First Start ID Ru...

Page 37: ...arameter group14 SPD LIM STRT LVL Parameter 14 01 will be the first selection ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the maximum speed Enter the maximum speed that the pump motor and system can operate at In most cases the maximum speed will be the same as the previously entered FULL LOAD RPM MAX SPEED d Full Load Motor RPM and d Pump...

Page 38: ... Consider x Turndown ratio x Pump minimum speed x Minimum flow The default value is 25 of the speed set in parameter 11 07 MOTOR FL RPM ENTER Press to complete the entry NOTES The default settings of the PumpSmart drive will stop the pump if the process demand requires the pump to operate below the minimum speed A LOW DEMAND Fault will be displayed in this case A delay can be set for up to 30 minu...

Page 39: ...pump suction can also be used PumpSmart can control the level in either a suction or discharge tank x Temperature OTHER used to maintain defined temperature of a process stream based on a temperature transmitter signal Also use this selection if a 4 20 ma signal from a different type of transmitter is used 11 03 MODE SELECT KEY SEQUENCE From parameter group 14SPD LIM STRT LVL OR Scroll to paramete...

Page 40: ...rect process variable 15 01 AI2 UNIT KEY SEQUENCE From parameter 11 03 MODE SELECT OR Scroll to parameter group 15 PROCESS VAR UNIT Parameter 15 01 will be the first selection Select the proper units of the operating mode Skip to the next step if the default unit is okay otherwise select ENTER Press to enter the parameter setting mode OR Scroll to the appropriate measurement units Example shown is...

Page 41: ... in this case The units of 16 03 are the same as selected in parameter 15 01 although they are not displayed NOTES Differential pressure flowmeters e g orifice plate venturi do not produce 4 20 mA signals that are linear with the flow rate PumpSmart refers to this as a QUADRATIC input Refer to the section DIFFERENTIAL FLOWMETERS in the options section for proper setup 16 03 AI2 MAX KEY SEQUENCE Fr...

Page 42: ...ep may be omitted since the default of parameter 16 04 is 0 16 04 AI2 MIN KEY SEQUENCE From parameter group 16 03 AI2 MAX OR Scroll to parameter 16 04 AI2 MIN ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the correct value Example shown 0 GPM Enter the reading of the primary process transmitter that corresponds to its 4 mA signal If your tra...

Page 43: ...rameter group 22 MULTI PUMP CTRL Parameter 22 01 will be the first selection ENTER Press to enter the parameter setting mode OR Scroll to the desired control mode Select the multi pump operating mode If your desired operation is SYNCHRONOUS skip to the next step Options SYNCHRONOUS Default MULTICONTROL CONSTANT SLV Slave BACKUP ENTER Press to complete the entry CONSTANT SLAVE MODE ONLY In Constant...

Page 44: ...mp starts 22 02 VALUE DECREASE The above figure shows a constant pressure system where Pump 2 is started when Pump 1 cannot maintain the constant pressure and it drops by the amount shown as VALUE DECREASE Considerations for VALUE DECREASE x Goulds recommends an initial value of 5 of your setpoint Example If the operating setpoint is 200 PSIG and a 5 VALUE DECREASE is entered into parameter 22 02 ...

Page 45: ...t VALUE DECREASE VALUE INCREASE Example If the original setpoint was 200 PSIG and the VALUE DECREASE was 5 a second pump would be activated at 190 PSIG A VALUE INCREASE of 5 would result in both pumps continuing to maintain constant pressure of 200 PSIG The VALUE INCREASE can be set higher than the VALUE DECREASE to compensate for added frictional losses that occur with increased flow 22 03 VALUE ...

Page 46: ...lly set to 98 of MAXIMUM SPEED This is the default setting ENTER Press to complete the entry REMOVING DE STAGING PUMPS As the system demand decreases the need for additional pumps will also decrease The SYNC parameters identify when pumps are de staged shutdown in normal multi pump control The primary consideration here is to ensure that when a lag pump is shutdown the remaining pumps are capable ...

Page 47: ... range between 0 100 Recommended values are automatically set based upon Multi Pump Mode selection ENTER Press to complete the entry 22 08 SYNC WINDOW KEY SEQUENCE From parameter group 22 07 SYNC LIMIT OR Scroll to parameter 22 08 SYNC WINDOW ENTER Press to enter the parameter setting mode OR OR Use the arrow key to scroll to the correct speed selection Enter the speed steps that the 2nd and 3rd L...

Page 48: ... is pre selected when FLOW LEVEL or TEMPERATURE is selected in parameter 11 03 MODE SELECT It may also be used for PRESSURE applications TRANSMITTER from ONE MASTER drive PumpSmart can also transmit the process transmitter signal to all of the slave drives via the fiber optic cables that link all the drives In this configuration the 4 20 mA signal is wired into the master drive and parameter 22 13...

Page 49: ...to the correct transmitter selection Select how you have wired in your process transmitter s TX ALL DRIVE Each drive has a transmitter TX ONE AI Each PS200 is wired in series with the transmitter TX ONE MASTER The transmitter signal is sent digitally through the fiber optic cables The default is based upon the selection made in 11 03 MODE SELECT ENTER Press to complete the entry ACT PAR FUNC DRIVE...

Page 50: ...nd setpoints to the PumpSmart unit from a remote location Variable Setpoint A second process transmitter 2 10VDC or 4 20 mA may be used to vary the setpoint The setpoint can be linear inverse linear or offset to this signal See OPTIONS FEATURES for details Multiple setpoint The PumpSmart system can be programmed with two setpoints and the drive can toggle between the two setpoints based upon a dig...

Page 51: ...ication is being controlled by pressure Flow switches are added to each pump installation and wired into its respective PumpSmart controller Once wired parameter 25 06 SECONDARY PROTECT A must be set to ALARM or ALARM AND CONTROL The response being 1 ALARM CONTOL In this response PumpSmart will issue a warning and then either shut down or reduce speed depending on the settings of parameter 14 05 C...

Page 52: ...ion 25 06 SECONDARY PROTECT A KEY SEQUENCE From parameter group 22 13 TX CONFIG OR Scroll to parameter group 25 PUMP PROTECT OR Scroll to parameter group 25 06 SECONDARY PROTECT A ENTER Press to enter the parameter setting mode OR Scroll to the desired response mode Secondary protect utilizes a process switch into connection DI 4 to warn of no flow conditions Once wired select ALARM CONTROL ALARM ...

Page 53: ...ly programmed ENTER Press to upload the drive parameters to the keypad With the drive parameters successfully loaded to the keypad remove it from the drive and connect it to the next drive in place of the original keypad Using the same basic process as uploading the parameters download the parameters to the new drive and replace the original keypad NOTE The drive to be downloaded must be set in th...

Page 54: ... the correct motor information ID MAGN REQ Each slave drive must have a First Start ID Run performed before the pump can be started 22 09 PUMP ADDRESS KEY SEQUENCE From parameter group 24 06 SEC PROTECT A PAR Press to enter parameter mode OR Scroll to parameter group 22 MULTI PUMP CTRL OR Scroll to parameter 22 09 PUMP ADDRESS ENTER Press to enter the parameter setting mode OR Use the arrow keys t...

Page 55: ... 17 21 AI2 CONFIG ENTER Press to enter the parameter setting mode OR Use the arrow keys to select transmitter configuration If TX ONE MASTER was selected in parameter 22 13 TX CONFIG set to NOT USED ENTER Press ENTER to complete the addressing Recommended Step Parameter Upload See KEYPAD USE Save your parameters to each individual keypad In the unlikely event that the PS200 parameters are lost the...

Page 56: ...be set to off Jogging the Motor for Rotation To check for proper motor rotation scroll to parameter 12 09 MOTOR JOG and selecting JOG Once selected PumpSmart will turn the motor at 60 RPM for 10 seconds For Multi Pump units the motor jog function should be done in Local Mode If rotation is reversed the position of two leads must be changed either at the drive output U2 V2 W2 or at the motor T1 T2 ...

Page 57: ... the inherent protection capabilities of the system Step Description Parameters Speed Control Overview 1 Locks Passwords 10 02 11 02 2 Motor Setup Drive data for the First Motor Run ID is entered here in addition to start stop methods and MAX and MIN drive speeds 12 01 11 04 11 05 11 07 11 08 14 01 14 02 3 Speed Control Setup Selects the units of operation and the operational limits 16 02 16 03 16...

Page 58: ...tpoint 10 02 PASS CODE KEY SEQUENCE From parameter group 99 INFORMATION PAR Press to enter parameter mode OR Scroll to parameter group 10 LOCKS PASSWORDS OR Scroll to parameter 10 02 PASS CODE ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the number 358 To open the Parameter lock scroll to parameter 10 02 and enter the passcode 358 The displ...

Page 59: ...0 02 LOCKS PASSWORDS OR Press to scroll to parameter group 11 START UP DATA OR Use the arrow key to scroll to parameter 11 02 APPLICATION MACRO ENTER Press to enter the parameter setting mode OR Use the arrow keys to scroll to speed control Select SPEED CTRL for manual speed control entry or PID Fieldbus entry ENTER Press to complete the entry ACT PAR FUNC DRIVE ENTER 1 L Æ 0 RPM 0 11 START UP DAT...

Page 60: ...itch or when an manual override switch is desired Three wire pulse start pulse stop Fieldbus control PumpSmart may be remotely started through a DCS system This option does require the optional Fieldbus communication module Refer to the FIELDBUS CONTROL option for further details 12 01 START STOP KEY SEQUENCE From parameter group 11 START UP DATA OR Scroll to parameter group 12 START STOP Paramete...

Page 61: ... a combination of the arrow keys to scroll to the nameplate motor voltage Enter the value for motor voltage and frequency Available selections are 208 VAC 60 Hz 220 VAC 50 Hz 220 VAC 60 Hz 230 VAC 60 Hz 380 VAC 50 Hz 415 VAC 50 Hz 460 VAC 60 Hz default 575 VAC 60 Hz OTHER Selecting OTHER will require entry in parameters 11 06 MOTOR NOM FREQ and 11 12 OTHER MOTOR VOLT ENTER Press to complete the en...

Page 62: ...a full load RPM of 1770 RPM ENTER Press to complete the entry 11 08 MOTOR NOM POWER KEY SEQUENCE From parameter group 11 07 MOTOR FL RPM OR Scroll to parameter 11 08 MOTOR NOM POWER ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the nameplate power Enter the nominal power HP or kW of the motor as found on the motor nameplate If you are using ...

Page 63: ...FORE STOPPING RESETTING THE DRIVE Although the motor may not appear to respond to the start command it has A warning message ID MAGN will be displayed during the ID Once the ID run is complete the message ID DONE will be displayed NOTE If the motor is changed in the future a First Start ID Run must be performed again to maintain the accuracy of the PumpSmart control Once the First Start ID Run has...

Page 64: ...r 14 01 will be the first selection ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the maximum speed Enter the maximum speed that the pump motor and system can operate at In most cases the maximum speed will be the same as the previously entered full load RPM MAX SPEED d Nominal Motor RPM and d Pump maximum speed The default value is the spee...

Page 65: ...INIMUM SPEED KEY SEQUENCE From parameter group 14 01 MAXIMUM SPEED OR Scroll to parameter 14 02 MINIMUM SPEED ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the minimum speed Enter the minimum speed that the pump and motor can safely operate at Consider x Turndown ratio x Pump minimum speed x Minimum flow The default value is 25 of the speed ...

Page 66: ...Keypad default A manually entered value Analog Input A 4 20mA signal is sent to PumpSmart Via AI 2 Fieldbus An operating speed is issued from DCS via a digital bus ENTER Press to complete the entry NOTE SETTING AI2 MAX 16 03 AND AI2 MIN 16 04 IS STILL REQUIRED IF USING KEYPAD OR FIELDBUS CONTROL If you are using an analog speed signal to set the operating speed of the pump signal MAX and MIN setti...

Page 67: ...mple If you want your process to run at 800 RPM when the 4 20 mA speed signal is 4 mA then you would enter in 800 into parameter 16 04 16 04 AI2 MIN KEY SEQUENCE From parameter group 16 03 AI2 MAX Scroll to parameter 16 04 AI2 MIN ENTER Press to enter the parameter setting mode OR OR Use a combination of the arrow keys to scroll to the correct value Example shown 800 RPM Enter the speed value that...

Page 68: ...g 4 20 mA may be used to send a speed signal to the PumpSmart unit from a remote location via Analog Input Multiple setpoint The PumpSmart system can be programmed with two speed setpoints and the drive can toggle between the two setpoints based upon a digital switch e g flow switch level switch manual switch etc Multiple setpoints can also be set through either the keypad Analog Input or via the ...

Page 69: ...toff protection Once wired parameter 25 06 SECONDARY PROTECT A must be set to ALARM or ALARM AND CONTROL The response being 1 ALARM CONTROL In this response PumpSmart will issue a warning and then either shut down or reduce speed depending on your settings If the PumpSmart controls to minimum speed on a secondary protection fault and the fault is reset the unit will resume normal operation If the ...

Page 70: ... utilizes a process switch into connection DI 4 to warn of no flow conditions Once wired select ALARM CONTROL ALARM ENTER Press to complete the entry Recommended Step Parameter Upload See KEYPAD USE Save your parameters in the keypad In the unlikely event that the PS200 parameters are lost the keypad can be used to restore the configuration It can also be used to program sister units that use the ...

Page 71: ...ou are now ready to start from a remote location KEY SEQUENCE LOC REM Press LOC REM button until L is displayed in the status row Press to start Press to stop Jogging the Motor for Rotation Once the ID MAGN has been completed jogging the motor to check for rotation may be performed by scrolling to parameter 12 09 MOTOR JOG and selecting JOG Once selected PumpSmart will turn the motor at 60 RPM for...

Page 72: ......

Page 73: ...ower Supply 78 Fieldbus Control 78 Language 79 Lead Lag Switching 79 Locking 80 Low NPSH Cavitation Protection 81 Manual Override 81 Minimum Speed Options 81 Motor Thermal Protection 83 Permissive 84 Priming Delay 84 Pump Wear Monitor PWM 84 Regulation Mode 85 Relay Outputs 85 Restart Options See Minimum Speed Options Secondary Protection 86 Sensor Failure 87 Setpoints Dual 88 Setpoints MultiVaria...

Page 74: ...I1 CONFIG NOT USED default Default setting PROC TRANS 1 Default setting SPD CTRL REF Used for speed control mode when external speed signal is present 17 21 AI2 CONFIG NOT USED Default for Speed Control mode VIBRATION 1 Used for Vibration signal 1 CONDITION 1 Used for general condition signal 1 PWM SIGNAL Used if a flow or pressure transmitter is required for the Pump Wear Monitor PROC TRANS 2 Use...

Page 75: ...AR ENERGY SAVNG Refer to Appendix A 3 PARAMETER LISTING for default scaling values for each selection 20 11 XT ANALOG OUT AI1 Note This selection requires the optional RAIO 01 module AND parameter 30 02 AI O MODULE set to slot module is mounted in NOT USED default SPEED FREQUENCY CURRENT TORQUE POWER VIBR LVL 1 VIBR LVL 2 COND LVL 1 COND LVL 2 PROC VAR ENERGY SAVNG Refer to Appendix A 3 PARAMETER ...

Page 76: ...d via the analog input channels that are available on the drive and through the optional RAIO 01 Analog I O Extension module The PS200 may accommodate up to four 4 4 20 mA signals for use as condition monitors Two of these signals are dedicated for vibration Overall RMS and two are general signals scaled as a percentage of the transmitters full range Primary Secondary Bearing Vibration IPS RMS VIB...

Page 77: ...open analog input channel except AI2 may be used for GENERAL CONDITION Example If a pump is being operated in basic single pump process then the primary process transmitter is wired through analog input channel AI2 If no vibration transmitter is being used the GENERAL CONDITION transmitter e g temperature could be wired into AI3 and configured as such in PumpSmart Parameter Name Value Range NOTES ...

Page 78: ...itical speed 14 11 CRITICAL SPEED 2 0 9999 RPM 0 Disabled default Refer to the pump manufacturer for second critical speed 14 12 NCR WIDTH 0 1000 RPM 0 default This is the total critical speed bandwidth above and below of the value set for Critical Speed 1 and 2 Digital Fault Reset There are several ways faults can be reset on the PumpSmart PS200 Methods include reset via the Keypad by Fieldbus or...

Page 79: ...P flowmeter 17 03 K DP FLOWMETER 0 1000 K values may be provided by the flowmeter manufacturer To calculate the K value refer to the equations provided below 17 04 SPECIFIC GRAVITY 0 0 10 Enter the process specific gravity here 15 01 OR 15 02 AI2 UNIT or AI1 UNIT PSIG BAR FT M Depending upon where the dP flowmeter is being used the units of parameter s 15 01 and 15 02 need to be changed Note param...

Page 80: ... is being used with a differential pressure transmitter The orifice plate is rated for 16 225 GPM and the dP pressure transmitter is scaled for 0 2 58 Ft The Resulting K value would be K 225 2 58 0 5 140 07 Note The dP transmitter full scale value 20 mA corresponds to a flow of 225 GPM Energy Savings Information PumpSmart can calculate the energy savings as compared to a constant speed pump applic...

Page 81: ...les allows selected PumpSmart parameters and operating signals to be accessed and modified Fieldbus control modules are available in numerous communication protocols including DeviceNet Modbus and Profibus With the control module installed set parameter 30 01 FIELDBUS to FIELDBUS If a Modbus Adapter RMBA is used set 30 01 FIELDBUS to STD MODBUS For FIELDBUS selection parameter Groups 31 MODULE TYP...

Page 82: ...sh with units of power in kW Parameter Name Value Range Note s 11 01 LANGUAGE ENGLISH ENGLISH AM DEUTSCH ITALIANO ESPANOL PORTUGUESE NEDERLANDS FRANCAIS DANSK SUOMI SVENSKA CESKY POLSKI ENGLISH AM is default setting Lead Lag Switching Automatically alternating the Lead Lag responsibilities of the drives in multi pump control may be accomplished by setting the parameter 22 05 SWITCH LEAD LAG to the...

Page 83: ...hen necessary To OPEN the parameter lock use parameter 10 02 10 02 PASS CODE 0 Using the arrow keys scroll to the number 358 and press enter This will open the parameter lock Note The number entry will disappear once ENTER has been pressed 10 03 LOCAL LOCK OFF default ON This parameter disables local control of the drive Start Stop It is not possible to stop the drive through the keypad with LOCAL...

Page 84: ... SWITCH POWER SOURCE DIGITAL SWITCH POWER SOURCE DIGITAL SWITCH GROUND SETPOINT SELECTION SECONDARY PRTCT B DIGITAL RESET SECONDARY PRTCT A THERMISTOR DIGITAL SWITCH GROUND DRIVE PERMISSIVE OPT OPT START STOP 2 WIRE HOA Configuration MANUAL OVERRIDE 2 WIRE HOA Configuration OPT OPT OPT OPT OPT OPT OPT OPT OPT EXAMPLE Hand OFF Auto EXAMPLE E Stop Permissive Minimum Speed Options When the PumpSmart ...

Page 85: ...r a period up to 1800 seconds before shutting down 14 07 RESTART VALUE 0 0 150 0 default If the drive is shutdown by CONFIG SPEED MIN 14 05 due to no system demand pressure control and level control modes only the drive will sleep until the process actual value drops below a set restart value 14 07 for longer than the restart delay 14 08 If operating in inverse mode 21 01 the drive will sleep unti...

Page 86: ...or resistance exceeds 4 kOhm If using a motor thermistor parameter 25 06 Secondary Protect A must be set to Thermistor NOTE Parameter 24 06 Motor Thermal P Mode will automatically update to the Thermistor setting Parameter Name Value Range Notes 25 06 SECONDARY PRTCT A DISABLED default ALARM CTRL THERMISTOR Select THERMISTOR when a motor thermistor is wired at DI4 WARNING According to IEC664 the c...

Page 87: ...onditions The characterization results are best when the system is in a normal operating condition When performing a baseline check the pump should be at or near its normal operating conditions with system temperature relatively stable NOTE Normal process control is suspended during the PWM characterization The characterization takes approximately 2 minutes to complete During this process a warnin...

Page 88: ...mation Switching capacity 8A at 24 VDC or 250 VAC 0 4 at 120 VDC Maximum continuous current 2 A RMS Refer to the ACS800 Hardware Manual for complete technical details Parameter Name Value Range NOTES NOT USED RUNNING READY Default for RO3 Default for RO2 Default for RO1 VFD FAULT A VFD related warning or fault has occurred PUMP FAULTS A general pump warning or fault has occurred ALL FAULTS Both Pu...

Page 89: ...ing controlled by an external speed signal A flow switch is added to the pump installation and wired into the PumpSmart controller This provides dry run and shutoff protection Once wired parameter 25 06 SECONDARY PROTECT A or 25 07 SECONDARY PROTECT B must be set to ALARM or ALARM AND CONTROL The response being 1 ALARM CONTOL In this response PumpSmart will issue a warning and then either shut dow...

Page 90: ...ose to the failed sensor signal as possible Warning if the transmitter fails low the pump may accelerate to Maximum Speed 14 01 FAULT Upon sensing an instrument failure PumpSmart will trip stop the drive and issue a fault message Parameter Name Value Range Notes 24 01 PROC SENSOR FAILURE DISABLED FAULT LAST SPEED default Applies to process transmitter inputs and analog setpoint inputs Failure mess...

Page 91: ...2 is coming from KEYPAD a number e g 100 will be manually entered via the keypad ANALOG INPUT The setpoint is entered using a signal through a configured analog input channel to establish the setpoint Selecting ANALOG INPUT will require entry of parameters 16 03 16 04 and 17 20 or 17 22 dependent upon input channel configuration EXAMPLE An application requires 150 GPM for a wash down application i...

Page 92: ...e MultiVariable Control function it is helpful to plot how you want your setpoint to behave in relation to the analog input signal PT PT Setpoint LOw INTeRCePT B Example 13 25 50 75 100 20 mA 10 VDC HIgh INTeRCePT B Example 100 0 4 mA 2 VDC PROC TX 1 MAX Example 150 PSIG SetPoint LOw TX2 Example 0 PSIG SetPoint LOw TX2 Example 150 PSIG SetPoint Example 100 PSIG Level of PROC TX 2 Signal LEVEL 1 Ex...

Page 93: ...EVEL 1 0 100 This defines the lower limit of the second process condition at which setpoint adjustment will occur This value is expressed as a percentage of the 4 20mA or 2 10VDC signal of the second process transmitter Example 25 8 mA or 4 VDC 21 04 SP LO TX2 20 000 0 default This is the desired setpoint when at a level defined by LO INTRCPT B This value is expressed in the same units as the setp...

Page 94: ...e Resulting System Curve Compensation System Curve Set Pressure Head Pressure Flow N 100 N N N N 0 In this case the system pressure setpoint is shown at shutoff and the increase in setpoint pressure is shown for increasing flow EXAMPLE If the setpoint is 150 Ft 65 PSIG 1 0 SG and the system resistance increase 10 Ft at the maximum flow rate or roughly 7 of the setpoint parameter 21 08 would be set...

Page 95: ... Relationship 50 12 mA 75 16 mA The effect is a straight relationship with the maximum setpoint value corresponds to the maximum signal i e 20 mA or 10 VDC while the minimum setpoint value corresponds to the minimum signal 4mA or 2 VDC Parameter Name Value Range NOTES 16 02 SETPOINT 1 SEL KEYPAD default ANALOG INPUT FIELDBUS Change to ANALOG INPUT if using an analog signal Select FIELDBUS if a var...

Page 96: ...STOP FUNCTION RAMP STOP default COAST STOP Selects how the motor will stop Test Run The TEST RUN capability allows the PumpSmart system to run periodically if it has been inactive The most common circumstance for which Test Run would be applied is when a standby pump is infrequently used the test run would allow lubrication of bearings and help verify if the unit is ready for operation The TEST RU...

Page 97: ...perating point serves as the reference torque from which the underload and overload conditions are compared to This point is normally the Best Efficiency Point BEP of the pump at its maximum speed The PumpSmart logic will calculate the reference operating point based upon the BEP power and speed The following chart depicts a typical ANSI pump performance and power curve 65 70 75 78 78 75 50 hp 40 ...

Page 98: ... as a percentage of the BEP Power The load at minimum flow may be determined prior to operation by graphical interpolation of the pump performance curve PumpSmart parameter 25 18 CALC TEST TRQ may also be used when the pump is operating This parameter will display the current torque as a percentage of the speed corrected BEP torque and may be used directly to set 25 12 MIN FLOW TORQUE Example An A...

Page 99: ...ssue a keypad warning and effect relay change if configured Alarm control will decrease pump speed so as not to exceed the runout torque limit If the unit reaches Minimum Speed it will attempt resets according to parameter 25 04 Error Reset 25 16 Runout Torque 0 201 201 default The load as percentage of BEP load when at a run out condition 25 17 Runout Ramp 5 100 seconds 20 seconds default The dec...

Page 100: ...per Pump Shaft Diameter in Single Inside Seal Losses Hp kW Double Inside Seal Losses Hp kW For between bearing pumps double the above values If the pump operation requires the pump minimum speed to operate below 33 of nameplate speed than it is recommended the final Power Offset value be determined by viewing the value of parameter 25 18 CALC TEST TORQ while the pump is operating The procedure is ...

Page 101: ...d offsets are likely It is important to note that the final values for the Proportional gain and Integral time should be determined not only for system changes but also for startup conditions For example a system tuned for system operating changes may be out of tune during startup conditions NOTE Air in the system may cause a condition that looks like oscillation or hunting Be sure all air is purg...

Page 102: ...ustment unless the drive response during ramp up or ramp down to the setpoint is unsatisfactory for the particular process If the default settings result in an unsatisfactory drive response the following rules of thumb can be applied x If rapid oscillations occur about the setpoint try increasing the value of the integral time parameter 13 04 first If the oscillations still continue or the time to...

Page 103: ...here is a slight overshoot to the setpoint however the response rate is better than the previous Normally Tuned system Setpoint Process Variable Time Over Compensated system In this case the drive is over compensating to the error in the setpoint resulting in an oscillation The proportional gain is too high and the integration time is too short ...

Page 104: ...rivative action will respond to a sudden change in process variable with a response similar to a high proportional gain but after this initial response behaves similar to a PI controller Derivative action will respond to a sudden change in process variable faster then by just using PI control In most pump applications PI control will be sufficient However PID control may be very useful in some lev...

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Page 106: ...e following is an overview of its use The keypad has five different display modes x Identification display x Actual Signal Display Mode x Parameter Mode x Function Mode x Drive Selection Mode IDENTIFICATION DISPLAY When the panel is connected for the first time or power is applied to the PS200 the identification display appears as shown below ACS800 0006_5SR ITT Goulds PS200 ID Number 1 After two ...

Page 107: ...ion Fault time 1 L Æ 0 0 RPM 0 1 LAST FAULT PANEL LOST 20 H 49 MIN 56 S Parameter group selection Fast Scroll OR Parameter selection Slow scroll OR PAR PARAMETER MODE Displays parameter settings Enter selection mode Accept new parameter ENTER Status Row Parameter group Parameter no Value 1 L Æ 0 0 RPM 0 10 LOCKS PASSWORDS 02 PASSCODE 358 Row selection OR FUNC FUNCTION MODE Program upload download ...

Page 108: ...display an active fault press the ACT key To reset a fault press the Reset key An Active Fault warning does not prevent the viewing and setting of parameters The Active Fault warning will remain until the condition that caused the fault has been cleared and the RESET key has been pressed Table 2 How to display a fault and reset the fault history Step Function Description Key Sequence Display after...

Page 109: ...oups ENTER 1 L Æ 0 0 RPM 0 1 VFD ACTUAL SIGNALS 02 MOTOR SPEED 0 0 RPM 4 Press the double arrow key to toggle between parameter group 01 VFD ACTUAL SIGNALS and group 02 PUMP ACTUAL SIGNALS OR 1 L Æ 0 0 RPM 0 2 PUMP ACTUAL SIGNALS 01 FLOW REF 0 0 GPM 5 Use the arrow keys to scroll through the available selections OR 1 L Æ 0 0 RPM 0 2 PUMP ACTUAL SIGNALS 12 ENERGY SAVINGS 0 00 6 Press and hold ENTER...

Page 110: ... select another parameter group While holding the arrow down only the group name and number are displayed When the key is released name number and value of the first parameter in the group is displayed OR 1 L Æ 0 0 rpm 0 10 LOCKS PASSWORDS 1 L Æ 0 0 rpm 0 10 LOCKS PASSWORDS 01 PARAMETER LOCK LOCKED 3 To select an index While holding the arrow down only the group name and number are displayed When ...

Page 111: ... 02 as the drive which had the upload It is recommended that parameter settings be verified after completion of each download Table 5 Typical Function Selection Step Function Description Key Sequence Display after key is pressed 1 Enter the Function Mode Selection FUNC 1 L Æ 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 2 To select a function OR 1 L Æ 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 3 To activate the sele...

Page 112: ...RAST 7 5 To send a new value to the drive To cancel the new setting and keep the original value press one of the mode keys PRIOR to pressing the ENTER key The selected Keypad Mode is entered ENTER ACT PAR FUNC DRIVE OR 1 L Æ 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 7 1 L Æ 0 0 rpm 0 UPLOAD DOWNLOAD CONTRAST 0 DRIVE DRIVE SELECTION MODE In normal use the features in Drive Selection Mode are not required ...

Page 113: ...es a start stop command given by an external source such as 2 wire or 3 wire start stop When in remote control the Setpoint can be changed from the keypad but the start stop commands must be given by the external source An empty field in the upper left hand corner of the status row indicates external control from an overriding system such as a Digital Communication System Operational commands cann...

Page 114: ...anged If the frequency converter is operated with the keypad detached the red LED in the keypad mounting platform indicates Fault condition Fault Resetting An active fault can be reset either by pressing the keypad RESET key by digital input or Fieldbus or switching the supply voltage off for a while When the fault has been removed the motor can be started A digital fault reset is available Refer ...

Page 115: ...diate circuit DC voltage is excessive DC overvoltage trip limit is 1 3 x U 1max where U 1max is the maximum value of the input power line voltage range For 400 V units U 1max is 415V For 500 V units U 1max is 500 V The actual voltage in the intermediate circuit corresponding to the input power line voltage trip level is 728 VDC for 400 V units and 877 VDC for 500 V units x Check that the overvolta...

Page 116: ...there are no power factor correction capacitors or surge absorbers in the motor cable connected to the drive output LOCAL CTRL LOSS Keypad or Drives Window selected as active control location has ceased communicating x Check Keypad connector x Reinsert Keypad in the mounting platform x Check Drives Window connection LOW DEMAND The setpoint value requires regulation below minimum speed x Check for ...

Page 117: ... The operating range limits are set by Parameter 14 01 DTC mode 14 03 Scalar mode x Check minimum maximum speed settings x Check adequacy of motor braking torque x Check applicability of torque control x Check the need for a Braking Chopper and Resistor s OVERSPEED Motor is turning faster than the highest allowed speed set with Parameter 14 01 OVERSPEED LIM This can be caused by an incorrectly set...

Page 118: ... or a rectifier bridge internal fault A trip occurs when the DC voltage ripple is 13 percent of the DC voltage x Check input power line fuses x Check for mains supply imbalance SYNCHRO SPEED The value of the motor nominal speed set to parameter 11 07 is not correct The value is too near the synchronous speed of the motor The tolerance is 0 1 x Check full load speed from motor rating plate and set ...

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Page 120: ...nput from AI2 mA of the Analog I O Module RAIO 01 optional X X X 1 43 MOTOR RUN TIME Motor run time counter Hrs since last reset The counter runs when the inverter modulates Re settable by parameter 26 05 X X X 1 44 FAN ON TIME Fan Operating hrs Resettable by parameter 145 13 if fan is replaced Speed Control Single Pump Multi pump Group 02 PUMP ACTUAL SIGNALS Description X X 2 01 Flow Ref Setpoint...

Page 121: ...dition Words PumpSmart condition monitoring words Group 03 Parameter STATUS WORD BIT NAME VALUE Description 0 Reserved 1 Enabled 1 ENABLE 0 Coast to stop 2 Reserved 1 Start 3 START STOP 0 Stop according to parameter 12 08 STOP FUNCTION 4 Reserved 5 Reserved 6 Reserved 7 Reserved 8 RESET FAULT 0o1 Reset drive pump fault 3 01 MAIN CTRL WORD 9 15 Reserved Group 03 Parameter STATUS WORD BIT NAME VALUE...

Page 122: ...ies refer to the section FAULT TRACING 3 Reserved 4 RUN DISABLED 5 ENCODER FLT 6 I O COMM 7 CTRL B TEMP 8 EXTERNAL FLT For possible causes and remedies refer to the section FAULT TRACING 9 OVER SWFREQ Switching overfrequency fault 10 15 AI MIN FUNC PPCC LINK COMM MODULE PANEL LOSS MOTOR STALL 3 06 FAULT WORD 2 MOTOR PHASE For possible causes and remedies refer to the section FAULT TRACING Group 03...

Page 123: ...to the section FAULT TRACING 3 09 ALARM WORD 2 14 15 Reserved Group 03 Parameter STATUS WORD BIT NAME Description 0 PUMP PROTECT WARN 1 LOW DEMAND WARN 2 DRY RUN 3 MIN FLOW 4 RUNOUT FLOW 5 LOW PERFORM 6 VFD FAULT 7 VIBRATION WARN 8 VIBRATION ALARM 9 CONDITION WARN 10 CONDITION ALARM 11 BASELINE RUN 12 TX AI ERR 13 SECONDARY PRTCT A WARN 3 10 PS ALARM WORDS 14 SECONDARY PRTCT B WARN For possible ca...

Page 124: ...ypad The lock can be opened by entering the valid password in parameter 10 02 When the keypad is locked the PS200 keypad functionality is limited to starting stopping and changing the setpoint X X X 10 02 PASS CODE Password setting 358 opens the lock and returns the value to zero on the display The password relocks when power is disconnected Range 0 30000 To re lock the keypad reset parameter 10 0...

Page 125: ... on the motor nameplate Selections are 460VAC 60Hz default 220VAC 50Hz 208VAC 60Hz 220VAC 60Hz 230VAC 60Hz 380VAC 50Hz 415VAC 50Hz 575VAC 60Hz and Other X X X 11 05 MOTOR NOM CURRENT Defines the motor current Equal to the value on the motor nameplate MOTOR NOM FREQ Visible only if Other is selected in 11 04 Defines the motor nominal frequency Equal to the value on the motor nameplate 60 HZ Nominal...

Page 126: ... the drive has not run for the test delay 12 05 the drive will start and run at 50 of maximum speed 14 01 for 20 seconds and shutdown Auto Restart 12 02 must be on X X X 12 03 MANUAL Once manual is selected the drive will start and run at test speed for 20 seconds and shutdown Once the manual test is complete this parameter will return to NOT SEL TEST SPEED FL Selects the speed the test runs at in...

Page 127: ...gulate at a speed at or below 14 02 MINIMUM SPEED SPD MINSPD The PS200 will stay at this speed until the transient clears or unit is manually shutdown unless a fault occurs X X X 14 05 SPD 0 default The drive will stay at minimum speed until 14 06 STP DELAY MIN SPD times out and then it will shutdown X X 14 06 STP DELAY MIN SPD The time period the drive will stay at 14 05 MINIMUM SPEED before stop...

Page 128: ...he units default is pressure for the primary process transmitter feedback located at AI2 In speed control macro default unit is rpm AI1 UNIT NONE default RPM HZ BAR GPM PSIG M3 HR FT M F DEG C DEG LBM SEC LBM MIN KG HR IN X X X 15 02 CM Selects the units for transmitter feedback at AI1 when used AI3 UNIT NONE default RPM HZ BAR GPM PSIG M3 HR FT M F DEG C DEG LBM SEC LBM MIN KG HR IN X X X 15 03 C...

Page 129: ...ing for parameter 17 04 Actual pressure signals in Ft M In or Cm are corrected for specific gravity by the firmware Signal can be quadratic or linear SETPOINT 2 SELECT Selects the signal source for Setpoint1 setpoint 2 KEYPAD default The setpoint is selected from the keypad ANALOG INPUT The setpoint is selected by an analog input AI1 AI2 or AI3 X X X 16 05 FIELDBUS The setpoint is selected via Fie...

Page 130: ...DC default 2VDC is selected as the minimum value TUNED VALUE Select tuned value after the tune function has been completed This will select the tuned value for the minimum value of AI1 X X X 17 05 TUNE This parameter sets the minimum value of the signal to be applied to AI1 When tune is selected and enter is pressed the tuned value for AI1 is set to the actual AI1 value when the tune function was ...

Page 131: ... 20 MA default Maximum scaled setting is at 20 MA TUNED VALUE Select tuned value after the tune function has been completed This will select the tuned value for the maximum value of AI3 X X X 17 16 TUNE This parameter sets the maximum value of the signal to be applied to AI3 When TUNE is selected and ENTER is pressed the tuned value for AI3 is set to the actual AI3 value when the tune function was...

Page 132: ...gnal XT AI1 NO No inversion X X X 18 07 YES Inversion is active The maximum value of the analog input signal 20 mA corresponds to the minimum vibration or condition level and the minimum value of the analog input signal 4 mA corresponds to the maximum vibration or condition value MINIMUM XT AI2 Defines the value for analog input XT AI2 Note parameter 30 02 AI O EXT MODULE must be set to RAIO Slot ...

Page 133: ...ay for relay output RO1 Setting Range 0 3600 sec Default 0 sec X X X 19 05 RO2 TON DELAY Defines the operation delay for relay output RO2 Setting Range 0 3600 sec Default 0 sec X X X 19 06 RO2 TOFFDELAY Defines the release delay for relay output RO2 Setting Range 0 3600 sec Default 0 sec RELAY RO3 OUTPUT Selects the PS200 status to be indicated through relay output 3 RO3 The relay energizes when t...

Page 134: ... 05 TORQUE Motor torque 20 mA 100 of motor nominal rating POWER Motor Power 20 mA 100 of motor power rating VIBR LVL 1 Vibration level 1 20 mA Vib 1 max value 23 03 VIBR LVL 2 Vibration level 2 20 mA Vib 2 max value 23 04 PROC VAR Actual value of process variable AI2 20 mA Setpoint 1 Max 16 03 ENERGY SAVING Calculated energy savings option 1 or 2 over a conventional fixed speed system 20 mA Saving...

Page 135: ...T AO2 Default 0 1 s X X X 20 20 SCALE XT AO2 Scales XT AO2 signal Default 100 Speed Control Single Pump Multi pump Group 21 REG MULTVAR Description REGULATION MODE Selects the type of PS200 control with falling process variable signal NORMAL default Increases the output speed with falling process variable signal For level control applications the tank is on the discharge side X X 21 01 INVERSE Dec...

Page 136: ...o synchronous multi control and slave modes only Default 98 of 14 01 MAXIMUM SPEED X 22 05 SWITCH LEAD Defines the time the lead unit will run before a new unit is deemed the lead unit Note if set to zero the switching function is disabled including switching during a fault Setting range 0 4000 hrs Default setting is 48 hrs SYNC ENABLE Selects if Sync Limit 22 07 and Sync Window 22 08 are used to ...

Page 137: ...1 MAX VAL Full scale vibration feedback 20 mA for Vib 1 Setting range 0 2 00 in s 50 8 mm s Default 1 0 in sec 25 4 mm sec Note parameter 30 02 AI O EXT MODULE must be set to YES if RAIO 01 module is used X X X 23 04 VIBRAT 2 MAX VAL Full scale vibration feedback 20 mA for Vib 2 Setting range 0 2 00 in s 50 8 mm s Default 1 0 in sec 25 4 mm sec Note parameter 30 02 AI O Ext Module must be set to y...

Page 138: ...tion is inactive FAULT The drive trips on fault and the motor coasts to a stop A fault message is generated EXT SP PROC XT1 SPD REF or PROC XT2 Err X X X 24 01 LAST SPEED default The drive generates a warning EXT SP PROC XT1 SPD REF or PROC XT2 ERR and freezes the speed to the average speed the drive was operating at over the last 60 seconds COND SNSR FAILURE Selects how the PS200 will react when ...

Page 139: ...X 24 09 ZERO SPEED LOAD Defines the load curve together by 24 08 and 24 10 X X X 24 10 BREAK POINT Defines the load curve together by 24 08 and 24 09 X X X 24 11 STALL FUNCTION Selects how the drive reacts to a motor stall condition Default NOT SEL Other choices WARNING FAULT X X X 24 12 STALL FREQ HI Defines the frequency limit for the stall function X X X 24 13 STALL TIME Defines the time for th...

Page 140: ... X X X 25 05 RESET DELAY The period of time that the PS200 will wait after an alarm and control condition before attempting an error reset Setting Range 250 sec Default 60 sec SECONDARY PROTECT A Loss of digital input 4 DI4 for 25 03 PROTECTION DELAY DISABLED default Protection is disabled ALARM The PS200 generates a warning only SECONDARY PROTECT A Relay outputs may be configured to change No oth...

Page 141: ...esettable by 25 04 ERROR RESET Value range setting is 0 200 Default 0 RUNOUT CTRL If enabled and the actual torque is greater than the runout torque corrected for speed for 25 03 PROTECTION DELAY a runout condition is indicated DISABLED default Protection is disabled WARNING The PS200 displays the message RUNOUT Relay outputs may be configured to change No other action is taken X X X 25 15 ALARM A...

Page 142: ...as degraded past the threshold value selected in 27 02 Relay outputs may be configured to change DISABLED Default The pump wear monitor is disabled 10 Warning given if the pump performance has degraded 10 15 Warning given if the pump performance has degraded 15 20 Warning given if the pump performance has degraded 20 X X X 27 02 25 Warning given if the pump performance has degraded 25 X X X 27 03 ...

Page 143: ...Single Pump Multi pump Group 31 FIELDBUS SETUP Description X X X 31 01 MODULE TYPE This parameter configures the module type automatically by the fieldbus adapter No action is required unless changes to default settings are desired Refer to the fieldbus manual This parameter becomes visible when FIELDBUS is selected in parameter 30 01 FIELDBUS Speed Control Single Pump Multi pump Group 50 MOTOR CO...

Page 144: ...pter manual for details on Fieldbus addressing X X X 90 01 MAIN DS REF2 Selects the address into which the value of Fieldbus reference Ref 2 is written X X X 90 02 AUX DS REF3 Selects the address into which the value of Fieldbus reference Ref 3 is written X X X 90 03 AUX DS REF4 Selects the address into which the value of Fieldbus reference Ref 4 is written X X X 90 04 AUX DS REF5 Selects the addr...

Page 145: ...ABLE LENGTH 10 m X X X 97 07 ZERO SPEED LIMIT 120 rpm X X X 97 08 SP ACT FILT TIME 8 ms X X X 97 09 PPCC FAULT MASK No X X X 97 10 LONG DIST MOD Off X X X 97 11 FREE DIRECT MAGN Off X X X 97 13 AMB TEMP FUNC Yes X X X 97 14 FREQ TRIP MARGIN 50 Hz Speed Control Single Pump Multi pump Group 99 INFORMATION Description X X X 99 01 SOFTWARE VERSION 4 0 Version of the software loaded to the PS200 X X X ...

Page 146: ...PS200 Configuration Operation Guide APPENDIX A 3 PARAMETER LISTING Page 143 ...

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Page 148: ...T USED X23 Terminal Block NOTE All instrumentation shielding must be terminated at grounding lugs provided by the PS200 Do not terminate Shielding at sensor end NOTE DIIL Must be closed for the drive to operate If your application does not require an E Stop Drive Permissive DIIL may be bypassed by jumping DIIL to X22 connections 7 or 8 OPTION 2 Wire Start Stop or Hand off Auto HOA Set Parameter 12...

Page 149: ...2 Vibration Transmitters Configuration Switch S2 XTAO1 1 XTA01 2 XTAO2 3 XTAO2 4 SHLD 5 SHLD 6 4 20 mA XT ANALOG OUTPUT 1 Configurable per parameter 20 11 SHLD Used for grounding control wiring shielding OUTPUT SELECTIONS 1 Speed 2 Frequency 3 Current 4 Torque 5 Power 6 Vibration 1 7 Vibration 2 8 Process Variable 9 Energy Savings 10 Condition 1 11 Condition 2 12 NOT USED 4 20 mA XT ANALOG OUTPUT ...

Page 150: ...IUS 2 Inches Extra cable may be looped and stored within the drive Maintain minimum bend radius Fiber optic cable ends are not the same color Fiber Optic Cable Kit Part Numbers 2 Pumps 800MP2 3 Pumps 800MP3 4 Pumps 800MP4 The RDCO 03 DDCS COMMUNICATION MODULE is to be mounted in the DDCS slot and affixed with 2 screws provided Copyright 2004 ITT Industries RO1 X25 Slave 1 RO2 X26 Slave 2 RO3 X27 S...

Page 151: ...turned off PumpSmart Powered Transmitter Pump 1 Pump 4 Pump 2 Pump 3 Externally Powered Transmitter T Pump 1 Master Drive 2 Drive 3 Drive 4 TX ONE AI One transmitter shared between all drives PumpSmart Powered Transmitter NOTES In this configuration a single process transmitter signal is wired in series with all the PumpSmart drives y Parameter 22 13 must be set to TX ONE AI y Communication connec...

Page 152: ...umentation shielding must be terminated at grounding lugs provided by the PS200 Do not terminate Shielding at sensor end NOTE DIIL Must be closed for the drive to operate If your application does not require an E Stop Drive Permissive DIIL may be bypassed by jumping DIIL to X22 connections 7 or 8 OPTION 2 Wire Start Stop or Hand off Auto HOA Set Parameter 12 01 to 2wire HOA Hand Jog AUTO start OPT...

Page 153: ... stored within the drive Maintain minimum bend radius Fiber optic cable ends are not the same color Fiber Optic Cable Kit Part Numbers 2 Pumps 800MP2 3 Pumps 800MP3 4 Pumps 800MP4 The RDCO 03 DDCS COMMUNICATION MODULE is to be mounted in the DDCS slot and affixed with 2 screws provided Copyright 2004 ITT Industries RO1 X25 Slave 1 RO2 X26 Slave 2 RO3 X27 Slave 3 Relay Output Specifications Switchi...

Page 154: ...ch S2 XTAO1 1 XTA01 2 XTAO2 3 XTAO2 4 SHLD 5 SHLD 6 4 20 mA XT ANALOG OUTPUT 1 Configurable per parameter 20 11 SHLD Used for grounding control wiring shielding OUTPUT SELECTIONS 1 Speed 2 Frequency 3 Current 4 Torque 5 Power 6 Vibration 1 7 Vibration 2 8 Process Variable 9 Energy Savings 10 Condition 1 11 Condition 2 12 NOT USED 4 20 mA XT ANALOG OUTPUT 2 Configurable per parameter 20 16 X23 Term...

Page 155: ...p 4 Pump 2 Pump 3 Externally Powered Transmitter T Pump 1 Master Drive 2 Drive 3 Drive 4 TX ONE AI One transmitter shared between all drives PumpSmart Powered Transmitter NOTES In this configuration a single process transmitter signal is wired in series with all the PumpSmart drives Parameter 22 13 must be set to TX ONE AI Communication connections must be made between drives Consideration s If on...

Page 156: ...e Minimum Distance 12 Inches 300 mm Minimum Distance 20 Inches 500 mm Keep control wiring perpendicular to power wiring Control Wiring Minimum Distance 8 Inches 200 mm WARNING Review the entire hardware manual prior to installation Mains Power Wiring General Notes 1 360o Grounded terminations are required 2 Ultra rapid fuses are required to protect drive Fuse operating time is to be less than 0 5 ...

Page 157: ...NEMA12 are bottom entry exit ACS 800 U2 NEMA1 is top entry exit Input and Motor Cable terminal sizes per phase and tightening torques are given below Two hole cable lugs 1 2 inch diameter can be used for U2 U7 models For 02 models one hole cable lugs inch diameter can be used The maximum allowed width of the cable lug is 1 5 inches Checked Tony Stavale Drawn AI 091003 Drawing is not to scale Dimen...

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Page 159: ...n Control Suction Level Control Cavitation Eliminate Control Valves Handle Wide Load Swings Multi Pump Control Remote Diagnostics Reduce HP Requirements PF700 3 200 HP Advanced pump protection Allen Bradley Powerflex 700 drive Maintain Constant Flow as Filters Clog Fewer Filter Changes No Flow Protection Control Pump Output Run Slower Run in Pump Sweet Spot Reduce Pump Wear Reboiler Bottoms Pumps ...

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ITT Industries PumpSmart PS200, Configuration & Operation Manual

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