DHQ RA Foundations - Drive Configuration & Programming

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Drive Configuration and

Programming
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Throughout this manual we use the following notes to make you aware of safety considerations:
Identifies information about practices or circumstances

that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
Identifies information that is critical for successful application and understanding of the product.
Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:
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Labels may be located on or inside the drive to alert people that dangerous voltage may be present.
Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.
Drive Configuration and Programming
Contents
Before you begin ........................................................................................................................................... 5
About this lab .................................................................................................................................................................................... 5
Tools & prerequisites ........................................................................................................................................................................ 5
Network Setup .................................................................................................................................. Error! Bookmark not defined.
Lab 1: Connected Components Workbench (CCW) Overview ..................................................................... 7

About Connected Components Workbench™ Software. .................................................................................................................. 7
Opening and downloading an existing offline project........................................................................................................................ 7
Adding a device to a project and uploading. ................................................................................................................................... 17
Using device configuration files. ..................................................................................................................................................... 21
Tech Support Wizard. ..................................................................................................................................................................... 27
Lab 2: Configuring the PowerFlex 525 AC Drive ........................................................................................ 30

About EtherNet/IP™ and Connected Components Workbench™ Software................................................................................... 30
Connecting to the Drive .................................................................................................................................................................. 30
Exploring Drive Parameters through Standard Parameter Groupings ............................................................................................ 33
Exploring Drive Parameters with AppView™ and CustomView™ Groupings ................................................................................ 37
PowerFlex 525 Drive Start-Up Wizard ............................................................................................................................................ 39
Lab 3: Configuring the PowerFlex 755TS AC Drive ................................................................................... 50

About EtherNet/IP™ and Connected Components Workbench™ Software................................................................................... 50
Connecting to the Drive .................................................................................................................................................................. 50
Exploring Drive Parameters through Standard Parameter Groupings ............................................................................................ 53
Predictive Maintenance................................................................................................................................................................... 60
PowerFlex 755T Drive Start-Up Wizard .......................................................................................................................................... 62
Using the Control Bar Tool.............................................................................................................................................................. 71
Lab 4: Drives Integration into Logix Designer ............................................................................................. 74

About Integrated Drive Profiles and Premier Integration ................................................................................................................ 74
Exploring the Add-On Profile for the PowerFlex 525 Drive ............................................................................................................. 75
Taking Advantage of Having the Drive in the Controller Organizer ................................................................................................ 81
Rockwell Automation | Foundations 3 of 160

Downloading the Project ................................................................................................................................................................. 83
Drive Automation Device Objects ................................................................................................................................................... 93
Lab 5: Trending in CCW............................................................................................................................ 108

Basic Setup and Operation ........................................................................................................................................................... 108
Advanced Setup and Operation .................................................................................................................................................... 126
Lab 6: Automatic Device Configuration (ADC) with the PowerFlex AC drives ......................................... 146
About Automatic Device Configuration (ADC) .............................................................................................................................. 146
Prepare the system for Automatic Device Configuration (ADC) ................................................................................................... 147
Exploring the Setup of Automatic Device Configuration (ADC) .................................................................................................... 150
Demonstrating Automatic Device Configuration ........................................................................................................................... 155

Before you begin
Please review the following information before starting this lab.
About this lab

Learn the basics of drive configuration and programming using the PowerFlex® 525 compact AC drive and the PowerFlex®
755TS AC drive. Attendees will configure these drives using Connected Components WorkbenchTM software and Studio 5000TM
Logix Designer software. You will also try out AppView, a feature that provides specific parameter groups for popular
applications for the PowerFlex 525 AC drive. In addition, this lab will show how Premier IntegrationTM enhances the use of
PowerFlex AC drives with ControlLogix® and CompactLogixTM controllers and other Allen-Bradley® products. You will also use
the Trending feature of Connected Components Workbench software to create useful troubleshooting trends for the PowerFlex
family of drives. Lastly, you will also learn about the Automatic Device Configuration, also known as ADC, feature for PowerFlex
750-series and PowerFlex 520-series drives in Studio 5000.
This lab takes approximately 180 minutes to complete.
Tools & prerequisites
Software programs required

 Studio 5000 Logix Designer – v34.00
 PowerFlex 525 Add-On Profile – v15.01
 PowerFlex 755T Add-On Profile – v15.01
 Connected Components Workbench – v20.01
 RSLinx Classic – v4.30.00
 Studio 5000 View Designer – v8.02
 FactoryTalk Linx – v6.30
Hardware devices featured

 CompactLogix 5380ERMS2 Controller – v34.011
 PowerFlex 525 AC Drive (25B-V2P5N104) – v7.001
 PowerFlex 755TS AC Drive (20G21NB4P2JAA6NNNNN) – v11.001
Files required
 PowerFlex_Lab_Enable.ACD
 PowerFlex_Lab.ACD / PowerFlex_Labv2.ACD
 PowerFlex_Lab_ADC.ACD / PowerFlex_Lab_ACDv2.ACD
 PowerFlex_Lab.VPD
Lab files are located within the “C:\PowerFlex Lab” folder.

Basic Setup Diagram
Network Setup Ethernet Connections
IP address of 755TS configured with switches. 1 PC L3100ERMS2 Port 1
2 L3100ERMS2 Port 2 PV5510 Ethernet Port 1
3 PV5510 Ethernet Port 2 AENTR Ethernet Port 1
4 AENTR Ethernet Port 2 PF755TS Ethernet Port 1
5 PF755TS Ethernet Port 2 PF525 Ethernet Port

Lab 1: Connected Components Workbench (CCW) Overview
About Connected Components Workbench™ Software.

Connected Components Workbench includes user-interface configuration tools for Micro800™ controllers, PowerFlex® drives,
Safety Relay devices, PanelView™ Component graphic terminals, and serial and network connectivity options.
In this section you will perform the following:
 Open an existing project and download parameters to a drive.
 Add a new drive to the project and upload parameters to the project from a drive.
 Create a backup parameter file and download it to the drive.
 Use the Tech Support Wizard to create a parameter listing that can be emailed to Tech Support.
Preparing the demo

To begin the lab we have to consider the safety configuration of the drive S4 safety option module. The S4 safety module is a
network based SIL rated safety option that requires a GuardLogix processor to function. Since this is a basic lab we are not using
any of the advanced features provided with S4 Safety. Typically in this situation the safety card would be removed, the safety
jumper installed on the drive main control board, and a drive reset and “fix” performed. To avoid making changes to the demo
hardware we will use a “safety enable” program that is downloaded to the PLC. This program will satisfy safety in the option
module and allow the drive to produce torque. Thus our first step is to download and run the safety enable program to allow the
drive to perform as if the safety option was not installed.
Skip steps 1-13 below if using a v2 demo (755TS demo box without 20-750-S4).
1. Double-click the Studio 5000 software icon on the desktop.
You will see the following splash screen.

2. From the splash screen, click “Existing Project” under the “Open” column and if prompted click “Project
File” (depending on installed software the second prompt may not occur).
3. Select the “PowerFlex_Lab_Enable.ACD” file and click the “Open” button ( if the .ACD files are not visible
ensure that the “Logix Designer” file extensions are selected)
The file will be opened in the Logix Designer software after a few moments.
Lab files are located within the “C:\ PowerFlex Lab” folder.

4. Click on “Communications” in the menu bar and select “Who Active”.
The Who Active window will appear.
5. Who Active is a feature of RSLinx that allows the user to browse the network devices and establish a
connection between the desired device and a personal computer. Verify that the node labeled
“192.168.1.32, 5069-L3100ERMS2” via the AB_ETH-1 Ethernet driver is selected and click the “Download”
button.
The Download window will appear.
6. When the confirmation window appears, click the “Download” button again.

You will see a progress bar
7. When prompted to change the controller mode back to “Remote Run”, click the “Yes” button.
8. Check for yellow triangle in the IO tree or a flashing IO Not Responding indicator. If a yellow triangle is
present follow the below steps. If there is not yellow triangle, proceed to step xxx.

9. Open the PowerFlex 755T PF755TS_Drive Add On Profile. You may right click on the drive and choose
“properties” OR double click the drive.
10. When the AOP opens (it will take a few seconds) click Safety Configuration. Note the Owned By indicates
??; click Reset Ownership.
11. In the pop up warning click YES.
12. After about a minute Owned By should now indicate Local. Close the drive Add On Profile by clicking OK

13. Minimize Logix Designer so that the desktop is visible.
Opening and downloading an existing offline CCW project.

Connected Components Workbench software allows you to create projects which can be accessed and modified when
disconnected from the device. Modifications can be made while offline and then downloaded to the device when connected.
The project file can also serve as a backup that can used when a device is replaced.
1. Go to the computer’s desktop and double click the shortcut for Connected Components Workbench
software.
You will see the following splash screen while the software loads, which may take a few moments.

2. The main screen for the Connected Components Workbench software is shown below.
You may need to maximize the window to make viewing easier.
3. There are many features in the Connected Components Workbench software. Mainly, we will be using the
features relevant to drives. Click Open Existing.

4. When the “Open” window appears, double click the “PowerFlex_Lab” folder.
5. Click on “PowerFlex_Lab” to highlight the file, then click Open.
6. When the file opens, a PowerFlex 755TS drive will be placed in the “Project Organizer”. Double click
“PowerFlex 755TS_IP75” to open the device’s configuration page.

7. Notice in the top right of the screen, there is a displayed IP Address. When you save a project that has
been connected to a device in the Project Organizer, the connection path for that device gets saved
automatically to save time when connecting to the same device in the future.
8. Click on the Info button to display the full path. Notice that there is an option to clear the path if desired
but do not clear the path. Click on the [x] to close the popup.
9. The Connect menu provides the ability to Upload the parameters from a working drive into the project,
Download the parameters from the project to the drive, or Synchronize the project and drive parameters.
Synchronize is a powerful feature that allows the user to choose which parameters get downloaded and
which parameters get uploaded. This drive has a network safety card installed in port 6 which will prevent a
download unless the safety card is disconnected. Rather than going through that process, use the
synchronize function to selectively download portions of this file to the drive. In the upper right corner click
Connect to open the menu and then click Synchronize.
10. For a brief moment, you will see a Synchronize progress bar while the parameter settings are being
uploaded and compared with those in the project.

11. CCW compares the parameters in the drive with those in the project and displays the ports with differences.
You can select “Use Project” to download the difference to the drive or “Use Physical” to update the project
with the settings in the drive. This can be selected on a port by port basis or as all ports with differences.
To update the parameters in the drive, click to place a check box in the “Use Project” column for all ports
except the Network SSM card or anywhere the “Use Project” box is greyed out to download those
parameters to the drive. For port 6 (safety card) or line items where “Use Project is greyed out, click to
place a check in the “Use Physical” column to update the project. Depending on the current state of the
drive, the differences you see could be different than the example shown below. If there are no
differences, you will not see this list and will transition directly to “Completed”.
12. Click “Continue” after the project / physical selections have been made.
13. If the Synchronize – Merge window appears, click “Reset”.
For Powerflex 755T, some drive settings (like motor control mode) require a drive reset to change.
Depending on the state of the drive before you synchronized, these settings may need to be changed to
match the project.

14. While synchronizing, the following status bar will appear, wait for the process to complete.
15. When complete, the “Download – Completed” window will appear. Click the “Finish” button to complete
the process.
Adding a device to a project and uploading.

CCW provides several options for adding devices to a project. In this section you will add the drive offline and then upload the
parameters to the project. This is useful for creating a backup of an already configured and running drive.
16. In the Project Organizer, click the Add Device button to open the Add Device window.
17. Expand the Drives folder by clicking on the arrow to the left of the folder.
18. Expand the PowerFlex 520-Series folder and highlight the PowerFlex 525 drive. When highlighted, click
Select.

19. If there were multiple devices you wanted to add to the project, you could follow the same procedure to add
them to the list. For now, you are only going to add the PowerFlex 525 drive. Click Add to Project to add
the drive and close the Add Device window.
20. The PowerFlex configuration page is automatically opened. Change the name to PowerFlex 525_IP60.
Leave the drive rating at the default single phase 110V .50 HP. Press OK when complete.

21. The drive overview screen appears. Notice that the default single phase 110V .50 HP PowerFlex 525 drive
was created. Also notice that there is not an IP address shown. This is because you have never connected
to that physical device with this project.
22. The Connect menu provides the ability to Upload the parameters from a working drive into the project,
Download the parameters in the project to the drive, or Synchronize the project and drive parameters.
which parameters get uploaded. You are now going to upload the drive configuration to the project. In the
upper right corner click Connect to open the menu and then click Upload.
23. The lab’s preconfigured RSLinx driver will appear. Click on the [+] to expand the topic AB_ETH-1,
Ethernet. Click to highlight the “192.168.1.60, PowerFlex 525 3P 460V 1.0HP” device.
24. Click “Continue” to initiate the upload process. For a brief moment, you will see an Upload progress bar
while the parameter settings are being uploaded from the drive.

25. When complete, the “Upload – Completed” window will appear. Click the “Finish” button to complete the
process.
26. Notice that the connection path was added and that the Drive Rating was updated to reflect the actual
hardware.
27. Click Save to save the project. The offline project now contains both drives attached to the station.
28. Close the file by clicking on File in the top menu bar to expand the file menu and then click Close.
Closing the file does not close CCW. To close CCW you would select Exit from the menu or click the X in
the top right corner.

Using device configuration files.
This feature allows you to save your drive configuration to a computer. It is useful for several reasons:
• You can use the configuration if you replace the drive or install an identical one
• You can use the configuration to troubleshoot the drive if it begins to malfunction because the settings have
changed
Uploading and Saving the Drive’s Configuration to a PC
29. On the Start Page, click Discover.
30. The lab’s preconfigured RSLinx driver will appear. RSLinx is a communication software that allows the user
to browse the network devices and establish a connection between the desired device and a personal
computer. Click on the [+] to expand the topic AB_ETH-1, Ethernet. Click to highlight the “192.168.1.75,
PowerFlex 755TS, PowerFlex 755TS” device.
31. Press the “OK” button to initiate the connection process. For a quick moment, you might see a connection
status window.

Otherwise, once the connection process is complete, you will see the following main screen with a green status bar across
the top of the PowerFlex 755TS window to indicate you are online with the drive.
Note: Your drive status may show “Faulted” instead of “Stopped”. This is normal and does not affect what
we are doing in the lab because we are not trying to run yet. Faults will be cleared later in the lab.
32. In the Overview category in Connected Components Workbench (CCW), click on the “Add to Project”
button.
The drive data will be uploaded and the drive will appear in the project window on the left.

33. Click on the “Device Definition” button to open the Device Definition window.
34. In the Device Definition window, click on the Export button to upload all the parameters from the PowerFlex
755TS drive and save the configuration file.
35. Give a name to your file and save on the desktop.

36. Click ‘Finish’ when the export completes.
37. Click OK to close the Device Definition window.
38. Disconnect from the drive by clicking on “Disconnect” under the Connect dropdown.
39. You should notice on the desktop that your saved file has an .iuux extension.

Downloading a saved Configuration CCW file to a Drive
40. Using what you learned previously, add a second PowerFlex 755T drive to your project. Notice that when
you created the new drive, CCW automatically opened the Device Configuration window. Name the new
drive PowerFlex 755T_New
41. In the Device Definition window, click on the “Import” button to load a configuration file into the offline
project.

42. Select your saved .iuux file.
43. The Import popup window will appear. This window will show you the ports that have parameter differences
and give you the option to only import the ports you want. By default, all ports with differences will be
selected for import. In this case, you want to import all differences so leave all boxes checked and click
“Continue”.
44. The import will happen fast. Once done , click the “Finish” button.
45. Click to close the Device Definition window. Notice that the new drive has been configured
exactly the same as the original. This includes all the Peripherals.

46. At this point, you would be able to download or synchronize with a new drive. Since we created the backup
from the drive, there is no need to perform the transfer because the drive is already configured the same as
the backup.
Tech Support Wizard.

This feature collects diagnostic information and the non-default drive parameters and saves it as a text file. It is useful for
several reasons:
• You can print out hard copies of the file and use it to compare to another drive.
• You can email the file to your remote technical support contact for assistance.
47. If not already connected to the drive, use what you have learned previously to connect to the PowerFlex
755TS.
48. In the bottom right corner click Help to expand the help menu then click Tech Support Wizard.
49. When the DPI/DSI Tech Support Wizard window opens, click Next to start collecting data.

50. A “Save As” window will appear. Give the file a name and save it to the Desktop by clicking Save.
51. The data being collected will scroll in the window. This will take a few minutes to complete.
52. When complete, click Finish to close the Tech Support Wizard window.

53. Locate the .txt file on your desktop and double click it to open the file.
54. Take a few minutes to explore the data in the file. You will see items like non-default parameters for all
ports, firmware revisions, and Fault History. Close the file when you are finished.
55. Close the Connected Component Workbench software.
Connected Components Workbench is a no cost, powerful tool that can be used to configure and troubleshoot the
PowerFlex family of drives.
You have completed this lab. Please stop here.

Lab 2: Configuring the PowerFlex 525 AC Drive
About EtherNet/IP™ and Connected Components Workbench™ Software

 Connect to the PowerFlex 525 drive through the embedded EtherNet/IP via Connected Components Workbench software
 Explore the different parameter groupings as well as the AppView.
 Create a CustomView
 Explore the Startup Wizard
Connecting to the Drive
software.

software to go online with the PowerFlex 525 drive. Click Discover.
PowerFlex 525 1P 110V .50HP” device.

status window.
the top of the PowerFlex 525 window to indicate you are online with the drive.

Exploring Drive Parameters through Standard Parameter Groupings
6. Some useful tools for the PowerFlex 525 drive are included in the Connected Components Workbench
software, as shown below.
Take some time to review what is there. Throughout the lab exercise, the different tools will be demonstrated.
7. Click on “Parameters” in the left pane to view the PowerFlex 525 drive parameters as seen below.
The PowerFlex 525 drive has a time saving feature with Connected Components Workbench software that will show the
non-default parameters. This makes it easy for users to view which parameters were changed from their default setting.
This button only updates the set of parameters shown based on the upload. When a parameter changes
from defaults after clicking the button, it won't be added to the list until the view is refreshed.

8. Make sure “0 – Powerflex 525” and “All Parameters” is selected within the Port and Group dropdown
selection boxes and then click the “Show Non-Defaults” button as shown below.
A progress window showing the upload may appear.
9. Once the upload has completed you will see the parameters window update to just show only the non-
default parameters. Take a look, you will notice that the communications parameters appear in this list.
10. Click the “Show All” button to return to viewing all of the PowerFlex 525 drive
parameters.

11. To make viewing and editing parameters even simpler, you can enter a word or abbreviation into the filter
value entry box. For example, type “motor” into the Filter Value entry box. Notice that it filters and only
shows the parameters that have the word motor in their parameter names. This is one of the time saving
features built into CCW software.
Try some other examples such as “Dig”, “Speed”, or “10” and see the results.
Remember to clear/delete the entry field when finished.
12. Click the arrow next to All Parameters and the arrow next to Parameters to view the dropdown list. Under
the Group dropdown selection box, you can scroll through the different drive parameter groups, AppView
groups and the CustomView group.

13. Select “Basic Program” from the Group dropdown menu and explore the parameters shown below.
These are the most simplistic parameters that are needed to start up/commission a PowerFlex 525 drive.
Take some time to explore some of the other parameter groupings such as “Terminals”, “Communications” and
“Advanced Program” for more startup and commissioning parameters.
In this exercise, how parameters are logically grouped was demonstrated. Parameter groups and filters make it easier to
locate the parameters you want to view or modify.

Exploring Drive Parameters with AppView™ and CustomView™ Groupings
The PowerFlex 525 drive has several AppView groupings that are tailored for a specific application to make the drive startup and
commissioning simpler. This reduces guesswork about which parameters you need to change, and all of the drive parameters
for that application are all in one convenient location.
14. Within the Group dropdown selection box, select the AppView parameter group for “Conveyor”. Scroll
through these application specific parameters.
15. The PowerFlex 525 drive has a CustomView parameter group which is an application set that can be
customized specifically for your application. You can add up to 100 parameters and save the new
CustomView group. Select “Custom Group” from the Group dropdown selection box and click on the
“Edit Group” button.

16. The Edit Custom Group window will appear. Here you will be able to select and add parameters into a
nameable custom group. In this example, type in “ABC’s Group” in the Group Name box highlighted
below.
17. Find the following parameters in the list and add them to “ABC’s Group”:
Parameter 30 - Language Parameter 43 - Minimum Freq
Parameter 31 - Motor NP Volts Parameter 44 - Maximum Freq
Parameter 32 - Motor NP Hertz Parameter 45 - Stop Mode
Parameter 33 - Motor OL Current Parameter 46 - Start Source 1
Parameter 34 - Motor NP FLA Parameter 47 - Speed Reference1
Parameter 35 - Motor NP Poles Parameter 62 - DigIn TermBlk 02
Parameter 36 - Motor NP RPM Parameter 63 - DigIn TermBlk 03
Parameter 37 - Motor NP Power Parameter 64 - 2-Wire Mode
Parameter 39 - Torque Perf Mode Parameter 65 - DigIn TermBlk 05
Parameter 40 - Autotune Parameter 76 - Relay Out1 Sel
Parameter 41 - Accel Time 1 Parameter 81 - Relay Out2 Sel
Parameter 42 - Decel Time 1

Once the parameters have been added, click the “OK” button to download this CustomView group to the drive.
You can also select/highlight multiple parameters then click the “Add - >” button. This makes adding
parameters go a lot faster.

18. Notice how the parameter entries from above are all now in the ABC’s Group CustomView for easy viewing
and editing of the parameters.
Application and custom groupings help accelerate commissioning by only showing the required parameters.
PowerFlex 525 Drive Start-Up Wizard

The drive Start-Up Wizard walks you through the most commonly used parameters to simplify the commissioning process. For
most applications, no further configuration is required.
19. Click on the “Wizards” category.
The Available Wizards selection box will appear.
20. Click in the “Start” button for the “PowerFlex 525 Startup Wizard” to launch the PowerFlex 525 Startup
Wizard.
After a moment, the Welcome screen for the PowerFlex 525 Startup Wizard will appear.

21. Click the “Next >” button to proceed with exploring the startup wizard.
22. Below is the Reset Parameters page. For this lab it is not necessary to reset the drive to default. The
options are described below. Click the first RESET option (See the Parameters Reset indication change to
yes and green checkmark). Click NEXT >to continue.
 Reset all settings to factory defaults but retain the custom parameter group.
 Reset all settings to factory defaults (including the custom parameter group).
 Reset only the “Power Parameters”.

23. Make sure “English” is selected in the Language dropdown selection box and Click the “Next >” button to
proceed to the next page…
24. On the next four pages, verify and if needed, modify the parameters according to the following screenshots.
At the end of each page, remember to click the “Next >” button to proceed to the next page.
 Motor Control Page
 Motor Data Page (changes required)

 Feedback Page
 Stop / Brake Mode Page

25. The next page is for the Direction Test. If desired, you may skip the Direction Test by clicking the “Next >”
button and move onto the next numbered step in this manual. To continue with the Direction Test, follow
the steps below.
Press the Stop button to Clear Faults if the drive is faulted. The button is shown below.
Press and hold the Jog button to run the Direction Test. The button is shown below.
Note: If the following window appears, click the “Yes” button.
If the motor rotation is in the correct direction, click on the “Yes” radio button.
Proceed to the next test by clicking the “Next >” button.

26. The next page is for the AutoTune. If desired, you may skip the AutoTune by clicking the “Next >” button
and move onto the next numbered step in this manual. To continue with the AutoTune, follow the steps
below.
Click on the “Rotate Tune” button highlighted below to initiate the AutoTune Test. It may take up to a minute to complete
after pressing the button.
Once finished, you will see the “Test Completed: Yes” result.
Proceed onto the next page by clicking the “Next >” button.

27. On the next several pages, verify and if needed, modify the parameters according to the following
screenshots. At the end of each page, remember to click the “Next >” button to proceed to the next page.
 Ramp Rates / Speed Limits
 Speed Reference #1
 EtherNet/IP

 Digital Inputs (changes required)
 Relay Outputs (changes required)

 Opto Outputs
 Analog Outputs
28. After stepping through the previous pages to the Pending Changes page, you can review a summary of the
planned programming changes you have made to the PowerFlex 525 drive.
Make sure all the pages have the check mark ( ) to the left of the page name / icon.
Click the “Finish >>” button to accept pending changes.

29. Click on the “Faults / Alarms” Category to open the Faults and Alarms page. Click the “Reset Device”
drop down button and select “0-PowerFlex 525” for all of the new parameter settings to take effect. Some
settings require a drive reset to activate them.
A window will appear confirming that you would like to reset the device.
Click the “OK” button. You will hear the PowerFlex 525 drive cycle power and the HIM Keypad display will turn off and on
before scrolling the drive information.
30. The reset happens quickly. While the computer is reconnecting to the drive, your screen may show the
following graphic for a moment.
After the connection has been established with the drive again, the window will return to the Overview category.

31. The configuration of the PowerFlex 525 is complete. At this point, we will be using the startup settings to run
the motor.
32. Keeping in mind that you now control the drive from two sources: the push buttons and potentiometer of the
drive, and the selector switches; attempt to run the drive.
You should start with the selector switched in the following position: Changing this position will change the start/stop and
direction source from drive HIM to demobox IO.
33. The control buttons located on the front of the PowerFlex 525 drive are as follows:
- starts the drive,
- varies the speed,
- changes the direction,
- stops the drive.
Take time to use the buttons to control the drive, vary the speed and change direction of the motor.
34. When you are done, return the switches to the position shown above (all to left).Close CCW.

Lab 3: Configuring the PowerFlex 755TS AC Drive
About EtherNet/IP™ and Connected Components Workbench™ Software

 Connect to the PowerFlex 755TS drive through the embedded EtherNet/IP via Connected Components Workbench
software
 Explore the different parameter groupings
 Explore the Startup Wizard
Connecting to the Drive
software.

You may need to maximize the software to make viewing easier.
software to go online with the PowerFlex 755TS drive. Click Discover.
PowerFlex 755TS, PowerFlex 755TS” device.

5. Press the “OK” button to initiate the connection process. Briefly, you might see a connection status
window.
the top of the PowerFlex 755T window to indicate you are online with the drive.

Exploring Drive Parameters through Standard Parameter Groupings
The PowerFlex 755TS drive limits which parameters are visible based on the motor control mode and application is selected to
make the drive startup and commissioning simpler. This helps to reduce guesswork about which parameters you need to
change. Parameters are grouped by Port number. When referring to parameters the convention is Port:Parameter.
6. The tools for the PowerFlex 755T drive are grouped by Category as shown below.
Take some time to review what is there. Throughout the lab exercise, the different tools will be demonstrated.
7. Observe how the Overview category displays important information about the drive, such as voltage and
amp ratings, series, revision, installed peripherals, and operational status. Click on “Edit peripherals….”
to see similar information about the peripherals themselves.

8. The Peripherals category in the Device Definition window shows all the peripherals installed or configured in
the drive. Peripherals are option cards and features that can be added to the drive. Click Replace to view
the available options for port 10. Click Add new peripheral to view the additional options Take some time to
explore them. Then click “Dynamic Features”
9. The Dynamic Features category in the Device Definition window shows the available software features in
the drive. Note these options were available from the Peripherals screen, that is because configuration of
features updates available drive ports just like changing a physical option module. Port 9 (Application port),
Port 10 (Primary Motor Control), Port 11 (Secondary Motor Control)
Changing feature selections requires a drive reboot. This is so the drive can change the available parameters to correspond
with the desired features. This allows for a more streamlined programming and troubleshooting experience. For this lab we
are leaving the selections as shown above.
When finished click to close the “Device Definition” window

10. You can view additional information about the drive and peripherals by clicking on the “Device Info”
category. This will show details about the hardware and firmware for each device. Take a couple minutes
to scroll down and see what is there.
11. Click on the “Parameters” category to view the PowerFlex 755TS drive parameters as seen below.
The PowerFlex 755T drive’s parameters window displays both read-only and writeable parameters. You can double click on
any of these parameters to view Value and Attributes. Double-click on Parameter 0:3 [DC Bus Volts] to view it.

This is a read-only parameter that displays the value of the DC Bus Volts. This value changes as the DC Bus Volts varies,
and you can see that here. Click ? to view the parameter help.
Parameter help provides additional descriptive information that is useful in drive programming / troubleshooting.
Take time to explore information for some of the other parameters, when done click X.
12. Scroll down even further to Parameter 10:1915 [VRef Accel Time 1], and then double-click on this
parameter to view and edit it.
This is a writeable parameter that determines the acceleration rate it takes to go from 0 Hz to Parameter 10:402 [Motor NP
Hertz] or Parameter 10:403 [Motor NP RPM], according to the setting in Parameter 0:46 [Velocity Units].
To edit this parameter, a new value would be entered, followed by clicking OK. In this case though, click Cancel.

Like PowerFlex 525, the PowerFlex 755T’s Add-On Profile has a time saving feature with Connected Components
Workbench software that will show the non-default parameters. This makes it easy for users to view which parameters
were changed from their default setting.
This button only updates the set of parameters shown based on the upload. When a parameter changes
from defaults after clicking the button, it won't be added to the list until the view is refreshed.
13. Make sure “All Ports” is selected within the dropdown selection box and then click the “Show Non-
Defaults” button as shown below.
14. You will see the parameters window update to just show only the non-default parameters. Take a look to
see which parameters are not at their default values. Your drive may show different non-default parameters
than those depicted below.

15. Click the “Show All” button to return to viewing all of the PowerFlex 755TS drive
parameters.
16. To make viewing and editing parameters even simpler, you can enter a word or abbreviation into the filter
value entry box. For example, type “motor” into the Filter Value entry box. Notice that it filters and only
shows the parameters that have the word motor in their parameter names.
Try some other examples such as “out”, “torque”, or “535” and see the results.
Remember to clear/delete the entry field when finished.
17. Under the Port dropdown selection box, select “10 – Induction FV”. The Parameter Group dropdown box
will become visible. Expand the Parameter Group dropdown box to see the available groups. You can also
expand the groups to see what items are available under each group.

18. Select “Velocity Ref” from the “Velocity” Group dropdown menu and explore the parameters shown
below.
You’ve just seen some of the parameters needed to start up/commission a PowerFlex 755TS drive. Take some time to
explore some of the other parameter groupings such as “Feedback”, “System”, “Dynamic Control” and “Diagnostics.”
The filter and parameter groupings make it easier to find the parameters needed.

Predictive Maintenance
The PowerFlex 755T drives have a feature known as Predictive Maintenance. This feature does not just look at time in service.
The algorithms also look at environmental conditions, temperatures, and current to better predict the remaining life for key
components of the drive system. The drives response to the predicted end of life, remaining life thresholds, and environmental
settings are configurable.
19. Click on the “Predictive Maintenance” category to display the components status.
Take a moment to scroll down and see the components the feature covers. Notice how catalog numbers are provided for
components that are field replaceable. The remaining life is displayed as hours as well as a bar graph showing percentage.
20. Click on the down arrow to expand Component Types. This will show you a list of component groups for the
drive and provides the ability to filter the view to only show components within that group. Expand the
groups to see the available options. This feature is useful when you have a large drive with multiple
components in each of the groups.

21. Click on “Environmental Settings” to open the Environmental Settings window. Here you can specify the
enclosure type and Airborne Contaminants classification. Click on each to see the available options. When
complete, click “Cancel”.
22. Click on “Notification Settings” to open the Notification Settings window. The “Remaining Life Threshold”
and “Remaining Left Threshold Action” are configurable for all component groups. Maximum Life is fixed for
the drive components but configurable for Bearings and Lubricants. Take some time to explore the different
groups. When complete, click “Cancel”.

PowerFlex 755T Drive Start-Up Wizard
23. Click on the “Wizards” category to launch the Wizard Browser and display the available wizards.
The PowerFlex 755T Startup Wizard is similar to performing the HIM Assisted Startup. Configuration parameters that are
common to most applications are displayed in text / graphic forms and presented in a sequential step-by-step process.
There are two common Wizards that do not show up in this category. They are the High Speed Trend
Wizard and the Tech Support Wizard.
The High Speed Trend will log up to 6 parameters in a single drive at ‘x’ intervals over ‘y’ time period. The
information is saved as a comma separated *.csv file for use with any spreadsheet program. It is accessed
by clicking on the button on the top of the “Overview” category.

The Tech Support Wizard is used to collect information for a remote support person to help troubleshoot a
problem. Drive and peripheral information such as series and revision are collected along with changed
parameters, fault & event queues, diagnostic items, etc. This information is saved to a text file which can be
emailed to RA Tech Support, the OEM that supplied the machine, or the Corporate Engineer responsible for
the remote plant, etc. This wizard is accessed by clicking on the button in the bottom right
corner.
24. Click on the button to the right of the PowerFlex 755T Startup Wizard.
The wizard will first upload the parameters for each of the wizard pages.

25. The first step in the wizard is the Welcome page. It explains the wizard and gives hints and tips for using
the wizard. It also has a button for resetting the drive to defaults. For this lab, we do not need to reset
defaults. Click Next to view the Drive Preferences settings. Continue to click Next until you reach the
Motor Control Mode Options step of the wizard.
26. The Motor Control Mode was pre-selected as Induction Flux Vector. Verify that the Speed Torque Position
Reference Mode A is set to “Speed Reg”. Continue to click Next until you reach the Motor Rating
Information step of the wizard.

27. Enter the motor nameplate information as shown below.
 Volts: 230.00 VAC
 Amps: 0.61 A
 Hertz: 60.00 Hz
 RPM: 1600 RPM
 Power Units: KW
 Power: 0.09 KW
 Overload Factor: 1.00
 Pole Count: 4
Click Next to get to the Speed Feedback step of the wizard.
28. Click the ellipsis beside Speed Feedback and configure the Port and Parameter as shown below. This will
configure the drive to use the encoder wired to channel 0 of the Dual Encoder card in port 4. Click Apply.

29. Clicking apply in the previous step added the configuration parameters for channel 0 of the Dual Encoder
card in port 4. The connected encoder is 1024 PPR (pulse per revolution) so the default configuration is
correct. Click Next to continue to the Stop Mode and Bus Regulation step of the wizard.
30. We will be using the default configuration for Stop Mode and Bus Regulation. Click Next to continue to the
Direction Test step of the wizard.

31. The Direction Test step is next. It helps you determine if the motor is rotating in the proper direction for your
application. Since we are using encoder feedback, we need to run the direction test so that the drive can
make sure the encoder direction motor rotation match.
If the drives Status is “Faulted”, click Clear Fault to clear all faults.
32. With the drive Status reporting “Stopped”, click Start to begin the test.
The direction test slowly rotates the motor. The wizard is looking for confirmation from you that it is rotating in the
correct direction for the application.

33. Verify that the motor is rotating in the forward direction. For the purpose of this lab assume it is rotating in
the forward direction. Click the Yes radio button and then click Apply.
34. Depending on how the encoder is wired, one of two popups will appear. The first option occurs if the
encoder polarity does not match the motor rotational direction. If this popup appears, leave the Yes radio
button selected to allow the drive to invert the encoder polarity and then click OK.
Clicking OK will stop the direction test to invert the polarity. Once the polarity has been inverted, the wizard will instruct you
press the Start to verify the change. Return to Step 31 to restart the direction test.
The second option appears if the encoder polarity matches the rotational direction of the motor. I this case click the OK
button to finish the test.

35. Verify that the Direction Test completed. Click NEXT to continue to the Motor ID Test.
36. The Motor ID Test step is next. This step runs automatic tuning algorithms (AutoTune) to identify the
electrical characteristics of the motor. When running these algorithms, the drive energizes the motor and
makes measurements, which are used to update parameter settings. We are going to run the Static Motor
ID Test. Click the down arrow beside “Rotate Tune” and select Static Tune.
Static Tune allows for measuring the motors electrical characteristics without requiring the motor to turn.
Rotate Tune requires the motor to rotate at 75% nameplate speed and may require the load to be uncoupled.

37. Leave “Torque %:” at its default value of 50.00 and click Start to begin the Motor ID test.
Leaving the Motor ID Test page while the test is in process will abort the test, faulting the drive. Do not leave the Motor ID
Test page until the test is complete:
38. When the test completes a window pops up to indicate the results, the wizard will also display the values
measured. Note that motors with identical part numbers may have slightly different electrical characteristics
so your values may be different than those shown below. Click OK in the pop-up window and Next a couple
times to advance to the Speed Reference step of the wizard.
39. The Speed Reference step is next. It helps you select where the drive gets its speed reference. Select the
reference to be from Port: 0, Parameter 211 – Emb Enet Ref. Click Apply to accept the new setting.
Click Next to continue to the Ramp Rates and Speed Limits step of the wizard.

40. The Ramp Rates and Speed Limits step is next. Make sure it is configured as shown below. Click Next to
advance to the Other Digital Inputs page the wizard.
Since there is no physical I/O wired to the drive, we do not have make any changes on the Other Digital Inputs page. Click
Next again to advance to the Summary step of the wizard.
41. The Summary step is the last. The purpose of this step is to verify all the changes you made in the wizard,
and then apply the changes to the drive. The screen below is for your reference, and there may be some
differences between your actual screen and the one shown.
Click Finish. If the Finish dialog box appears, click YES.

The wizard will write your changes to the drive.
The Summary step can be used as a reference tool. You can print the summary and refer to the printed
summary when commissioning duplicate drives or replacing a faulted drive.
The Start-up Wizard expedites the commissioning process by stepping through the parameters most commonly used. If
additional configuration is required, that can be accomplished after running the wizard by utilizing the parameter groups.
Using the Control Bar Tool
42. Verify Parameter 0:30 [Access Level] is set to Expert to allow all of the parameters to be visible.
43. The PowerFlex 755T has a feature named Load Observer that automatically adjusts drive response based
on connected load inertia. Motor inertia must be accurate to maximize Load Observer performance. If the
motor is disconnected from the load, the drive can accurately measure motor inertia. In our case, we have
the manufacturers design values. Change parameter 10:900 [Motor Inertia] to 0.000347 kgm2.

44. Click on the button near the bottom of the window.
45. Read the Caution Advisory window and click OK.
46. Use the buttons on the left-hand side of the control bar to start, stop, jog, and control the direction of the
drive. Drive will jog according to the parameter setting inputted during the set-up wizard.
Use the slider on the right-hand side to control the speed reference when the drive is running (Start not Jog).

47. Stop the drive and turn off the control bar by clicking the button. Observe the Caution
Advisory window and click Yes.
48. Close the Connected Component Workbench software.

Connected Components Workbench software has many time saving features that facilitate a faster and simpler
commissioning experience. Parameter groupings and the Start-up Wizard are a couple of these time savers that were
demonstrated in this lab exercise. Another handy tool that was covered is the control bar that allows for testing the
configuration while commissioning.

Lab 4: Drives Integration into Logix Designer
About Integrated Drive Profiles and Premier Integration

Integrated Drive Profiles are designed to save system development time and to make systems easier to maintain.
Tests were conducted utilizing skilled engineers to configure drives in a timed, side-by-side comparison. The results show that
Integrated Drive Profiles in RSLogix 5000 and Studio 5000 Logix Designer software can reduce drive system development time
by as much as 70% compared to traditional configuration methods.
This is achieved by:
 Providing one software tool to configure the entire controller and drive system.
 Configuring both controller and drive network connections from a single location – eliminating I/O mismatch errors.
 Allowing the dynamic selection of drive parameters transmitted as network I/O – communicating only what is needed for
the application.
 Auto-generating descriptive tag names – eliminating the need to enter individual tag descriptions.
 Auto-generating respective tag data types – eliminating the need to convert from one data type to another.
 Saving all drive configurations in the project file and in the controller – providing a single source of drive configuration
data.
 Providing Copy & Paste capability when creating additional duplicate drives – reduces errors in configuration with
systems containing multiple identical drives.
 Using the same easy-to-use drive configuration Wizards in the Connected Components Workbench software package.
Systems using the Integrated Drive Profiles in RSLogix 5000 and Studio 5000 Logix Designer software are also easier to
maintain:
 Drive diagnostics, faults, alarms and event information is integral to RSLogix 5000 and Studio 5000 Logix Designer
software.
 Drive Tech Support Wizard can be run from RSLogix 5000 and Studio 5000 Logix Designer software to collect all
pertinent information about a drive, its peripherals, various software components, and PC operating system.
 Drives can be flash updated from RSLogix 5000 and Studio 5000 Logix Designer software.
 Having a single repository of drive configuration data in the controller project file reduces downtime by speeding drive
replacement.
Integrated Drive Profiles are "Add-On Profiles", independent of particular releases of RSLogix 5000 and Studio 5000 Logix
Designer software. Many are backward compatible to work with previous versions of the programming software as well, helping
to prevent obsolescence of the controller when newer drives are available.

Exploring the Add-On Profile for the PowerFlex 525 Drive
1. Start the program. Double-click the Studio 5000 software icon on the desktop.
2. A pre-configured Studio 5000 Logix Designer software project has already been created for your
convenience. From the splash screen, click “Existing Project” under the “Open” column and if prompted
click “Project File” (depending on installed software the second prompt may not occur).

3. Select the “PowerFlex_Lab.ACD” file and click the “Open” button ( if the .ACD files are not visible ensure
that the “Logix Designer” file extensions are selected). If using a v2 755TS demobox (755TS drive without
20-750-S4) use the file “PowerFlex_Labv2.ACD”.
Lab files are located within the “C:\Lab Files\PowerFlex Lab” folder.
4. In the Controller Organizer, scroll down to the I/O Configuration section shown in the graphic below. Open
the Module Properties window for the drive by double-clicking on the “PowerFlex 525-EENET
PF525_Drive”.
The Module Properties window will appear. The Add-On Profile for the PowerFlex 525 drive in the Logix Designer software
provides a common look-and-feel to the Connected Components Workbench software. This Logix Designer tool provides
the same ability to upload, download, view, modify, and compare drive parameters, as well as access the Wizards without
requiring an additional software package.

Click on the “Device Definition” button.
One additional feature in Logix Designer is for setting up Automatic Device Configuration (ADC) for the drive. ADC is a
powerful feature that automatically configures drive product upon power-up when required. Details about ADC are covered
in the Automatic Device Configuration lab.
5. Now let’s look at the PowerFlex 755TS. In the Controller Organizer, double-click on the “PowerFlex 755T
PF755TS_Drive”.

6. The Module Properties window appears and displays the Overview category of the PowerFlex 755TS.
The Add-On Profile for the PowerFlex 755T drive in the Logix Designer software provides a common look-and-feel to the
Connected Components Workbench software. This provides the same ability to upload, download, view, and compare drive
parameters, as well as access the Wizards. One additional feature in Logix Designer is for setting up Automatic Device
Configuration (ADC) for the drive.
7. The tools for the PowerFlex 755T are functionally grouped by category as shown below:

8. Click on ‘Device Definition’ underneath the drive description. This will open the drive ‘Identity” window that
allows you to view/edit important information such as: voltage and amp ratings, series, and revision.
Within the Module Definition window, you can perform the following actions:
 Set the Revision of the drive firmware, and set the Electronic Keying
 Select the Drive Rating, Rating Options, and Drive Type
 Create database files from the online drive or download database files from the web
 Configure the input and output datalinks
9. Click on ‘Peripherals’ to view the peripherals installed in the drive. Expand each port peripheral to review
the port, series, revision, and electronic keying. Within this window, you can also add, edit, and delete
peripheral devices as required.

10. Click on ‘Dynamic Features’ to view/edit Motor Control Mode, select an application type, or to enable
DeviceLogix. The PowerFlex 755T family can be configured for two different motors. While it can only
control one motor at a time, having two separate configuration ports allows the drive to be used as a spare
for two different applications. We will only be using the Primary configuration in this lab.
11. Click on ‘Connection Format’ to view/edit the input and output datalinks configured for the drive. When
you add a drive to the I/O configuration in Logix Designer, a standard I/O structure is created. Datalinks
allow for customizing the tag structure by providing the ability to add parameters required for the application.
Close the PowerFlex 755T Module Properties window

The Add On Profiles have the same look and feel as Connected Components Workbench which provides a simplified user
experience for interfacing with the drives

Taking Advantage of Having the Drive in the Controller Organizer
When your application requires more than one drive, you can save time with Studio 5000 for configuration. Within the Controller
Organizer, you can duplicate the PowerFlex 525 drive or the PowerFlex 755TS drive on the Ethernet network as many times as
needed by using the Copy and Paste features. All of the node information is copied, including the drive parameter settings. All
you need to do is change the IP address, and give the device a unique name. Integrated Drive Profiles are not only easy to use;
they also allow larger systems to be designed faster. Additional devices can be added to the I/O tree by right clicking on the
“Ethernet” and selecting ‘New Module’. There you can search for the device that you are looking to add.
12. Open the contextual menu by right-clicking on the device and select “Copy”.
13. Select the A1/A2, Ethernet and right-click to show the network menu. Select “Paste” from the list.
14. The new drive will appear. It will not have a valid IP address, but the name will be an incremented value of
the original drive.
Where do you think the drive configuration data gets stored? The drive configuration data for each node is
actually stored in your Logix Designer project! It also resides in the controller after the project is downloaded.
This provides a convenient local resource for a node’s configuration settings if the drive needs to be
replaced. Just connect to the controller, open the drive’s AOP, and download the configuration!

15. In addition to storing configuration data, the controller manages communications with the drive using
convenient tag-based addressing. Double-click on the “Controller Tags” icon under the “Controller
PowerFlex_Lab” folder.
The Monitor Tags window will appear.
16. Find the tag for “PF525_Drive:I” and expand it by clicking on the [+] next to the name. It may help to
change the width of the “Name” and “Value” columns to view the tag names and values more easily.
Descriptive tag names have been created for the configured drive, based on the module definition. The Drive Status bits
(BOOLs) are clearly defined as well as the “OutputFreq” and “OutputCurrent” (defined as one of the Input Datalinks). Note
that the proper data types are automatically used for every tag.
17. Now expand the “PF525_Drive:O” tag to view the output tag names.

Descriptive tag names have been created for the drive again. The Logic Command bits (BOOLs) are clearly defined as well
as the “FreqCommand” value for applying a reference to the drive. The proper data types are automatically used for every
tag.
18. Close the Studio 5000 Logix Designer project.
Click “No” when prompted to save changes to the project.
When drives are added to the I/O configuration, descriptive tag names are automatically generated for the most common
parameters used for control. This saves significant time during development of a project.
Downloading the Project
19. Open the PowerFlex_Lab project. Click the “Open” icon illustrated below.

20. Select the “PowerFlex_Lab.ACD” file and click the “Open” button. If using a v2 755TS demo box (755TS
drive without 20-750-S4) use the file “PowerFlex_Labv2.ACD”.
21. Open the drive Module Properties window by double-clicking on the “PowerFlex 525-EENET
PF525_Drive” node in the I/O Configuration folder.
The Module Properties window will appear.
22. Click on “Connect”.

23. The Connect menu provide the ability to Upload the parameters from a working drive into the project,
which parameters get uploaded. Click on “Download”.
The Connection Browser window will appear.
24. Expand the “AB_ETH-1” Ethernet driver and select the “192.168.1.60, PowerFlex 525” node.
Click the “Continue” button
25. For a brief moment, you will see a Download progress bar while the parameter settings are being
downloaded to the drive.
26. When complete, the “Download – Completed” window will appear. Click the “Finish” button to complete
the process.
You may hear the drive reset, which is normal.

27. Click the “OK” button to close the Module Properties window.
28. Open the drive Module Properties window by double-clicking on the “PowerFlex 755T PF755TS_Drive”
node in the I/O Configuration folder.
29. Click on the “Connect”.
30. The Connect menu provide the ability to Upload the parameters from a working drive into the project,
which parameters get uploaded. Click on “Synchronize”.

31. From the “Synchronize” window, select the “192.168.1.75, PowerFlex 755TS” node.
32. Click “Continue”.
33. You will be shown all ports with differences between the Project and Physical device. To update the
parameters in the drive, click to place a check box in the “Use Project” column for all ports except the
Network SSM card or anywhere the “Use Project” box is greyed out to download those parameters to the
drive. For port 6 (safety card) or line items where “Use Project is greyed out, click to place a check in the
“Use Physical” column to update the project. Depending on the current state of the drive, the
differences you see could be different than the example shown below. If there are no differences, you
will not see this list and will transition directly to “Completed”.
34. Click “Continue”, which will quickly complete the download.
35. When the Synchronize completes, click “Finish”.
36. Click “OK” on the module properties window.

“192.168.1.32, 5069-L3100ERMS2” via the AB_ETH-1 Ethernet driver is selected and click the “Download”
button.

42. Open the “Lab Files\PowerFlex Lab” folder on the desktop.
43. Double click on the file named “PowerFlex_Lab.VPD” to open the View Designer application. View
Designer is the visualization tool included as part of the Studio 5000 software suite.
You will see the splash screen while View Designer loads

44. When the application opens, click on the “Download Project” button in the top menu to download the
application to the PanelView.
45. When the Download Runtime Application screen appears verify the address 192.168.1.101 and click
Download
46. You will see the following screen when the download completes;click Close.

47. When complete you will see the following screen on the PanelView.
48. Click on the I/O button on the banner.
49. When a device is configured in the I/O tree of Logix Designer, the controller owns the device and limits the
functionality available in other software packages and via the Human Interface Module (HIM). Logix
Designer has a feature that allows users to temporarily inhibit the connection so that the device can be
controlled by the HIM or other software. When the connection is inhibited, the controller cannot send
commands to the device. From the I/O window, click on the PF525 Connection and PF755TS Connection
selector switches to uninhibit both the PowerFlex 525 and PowerFlex 755TS.
50. Click on the Home button on the banner to return to the main screen.
51. To clear the faults after downloading the program, press the “Clear” button.

52. The ribbon at the top will now read “Machine Healthy” instead of “Machine Faulted”. Press the “Reset”
button to reset the system.
53. The system is now in the “Idle” state. Press the “Start” button to start both drives.

54. Verify that the state is “Execute” and both motors are rotating. Press the “Stop” button to stop both
drives.
Drive Automation Device Objects

About Automation Device Objects
Automation Device Objects (ADO) provide a common control interface between application code and physical automation
devices. The ADO library contains View Designer Faceplates and Logix Designer configuration and logic. The ADOs were
developed and are maintained by Rockwell Automation.
Having this common interface allows standard application code to be developed and applied across multiple device platforms.
In this exercise, you will perform the following:
 Review the Logix Designer Configuration.
 Explore the Logix Designer logic.
 Use the View Designer faceplates to interact with the device.
Configuration
55. If not already online with the controller, using what you learned in the previous exercise, open the
PowerFlex_Lab project and connect to the controller. If prompted to either upload or download, choose
download. If using a v2 755TS demobox (755TS drive without 20-750-S4) use the file
“PowerFlex_Labv2.ACD”.

56. For this exercise, you will explore the PowerFlex 755T ADO. In the Controller Organizer, scroll down to the
I/O Configuration section shown in the graphic below. Open the Module Properties window for the drive by
double-clicking on the “PowerFlex 755T PF755TS_Drive”.
57. If there are any parameter differences that cause the Merge window to appear, select “Use Physical” for all
ports and the click Continue.
58. After the drive finishes connecting, click the “Device Definition” button.
59. When the “Device Definition” window opens, click on the Connection Format category.

60. The tag structure that gets automatically generated when a drive is added to the I/O Configuration can be
customized to include additional parameters. This customization is accomplished by a feature known as
datalinks. The Connection Format category is where the datalinks are configured. The functionality in the
ADOs requires “Input” datalinks to be configured for full functionality. They must be added to the
configuration in the order shown. Additional Input and Output datalinks can be configured but they must be
added after the ones shown below. Make note of what datalinks are configured and click on the Cancel
button when complete.
Note: Different drive products require different datalink configurations. The required datalinks are specified
in the specific drive ADO documentation.
61. Click on the Cancel button to close the module configuration.

Logic
ControlLogix organizes logic in Tasks. Tasks can run repeatedly (Continuous), at a defined time interval (Periodic), or as the
result of a programmed trigger (Event). The naming of tasks usually follows some standard. For example, in this project, there
is a task named “ms0010p10”. The “ms0010” indicates that it is a Periodic Task with a period of 10ms. The “p10” indicates that
is has a priority of 10 (lowest).
Underneath the task are Programs. Programs provide the ability to group logic for a section of a machine or line to aid in
development and troubleshooting. For example, in this project, there is a program named “EM02_PF755TS” that contains the
logic required to operate the PowerFlex 755TS drive.
Below programs are Routines. Routines allow for grouping of functions within the program. This is useful because many
sections of the machine or line may have the same functionality which could be quickly and easily duplicated by copying the
routine and pasting it into multiple programs. For example, in this project, there is a routine named “_EP_ClearFaults” that is
utilized in multiple programs. The routine is used to reset the faults and prepare the drive to run.
62. In the task “ms0010p10”, expand the program “EM02_PF755TS”. Double click the routine
“_Dvc_Drive01” to open the routine.
63. Rungs 0 and 1 are all that is required to interface with the View Designer faceplate. The remainder of the
rungs in this routine are application specific. For example, rung 2 is used to annunciate a drive fault on the
pre-configured “AlarmSummary” screen in View Designer. Rungs 3 and 4 are used to annunciate when the
drive has a “Start Inhibit” condition. Rungs 5 through 12 are for the “Connection Status” indicator on the
main screen of the HMI. Rungs 13 through 18 allow you to power cycle and inhibit the drive from the HMI.

64. The Add-On Instruction (AOI) “raC_Dvc_PF755T” not only interfaces with the View Designer faceplate but
also has parameters that follow the common interface standard which allow you to control the drive with
logic. Let’s take a look.
65. Double click “Parameters and Local Tags” for program “EM02_PF755TS” to open the tag database
explorer.
66. Scroll down the list and click on the arrow beside “PF755TS_CtrlCmd” to expand the tag so that you can
see the sub elements.
67. Review the elements of the tag. Their usage is as follows:

 PF755TS_CtrlCmd.bCmd – summation of BOOL elements in INT format
 PF755TS_CtrlCmd.Physical – Command the AOI to interface with the physical drive.
 PF755TS_CtrlCmd.Virtual – Command the AOI to interface with a virtual drive for testing.
 PF755TS_CtrlCmd.ResetWarn – Clear any drive warnings.
 PF755TS_CtrlCmd.ResetFault – Clear any drive faults.
 PF755TS_CtrlCmd.Activate – Enable power structure and run at fixed speed.
 PF755TS_CtrlCmd.Deactivate – Stop drive and disable power structure.
 PF755TS_CtrlCmd.CmdDir – Direction of motor rotation (0=Fwd 1=Rev).

68. Leaving PF755TS_CtrlCmd expanded, click on the arrow next to “PF755TS_CtrlSet” to expand the tag so
that you can see the sub elements.
69. Review the elements of the tag. Their usage is as follows:

 PF755TS_CtrlSet.InhibitCmd – Enables/Disables commands from the faceplate (1=disabled)
 PF755TS_CtrlSet.InhibitSet – Enables/Disables ability to change speed from the faceplate (1=disabled).
 PF755TS_CtrlSet.Speed – Drive run speed in Hz
70. As done with the previous tags, expand and review the sub elements of “PF755TS_CtrlSts”. The elements
show drive status based on the commands given.
71. Now let’s try to run the drive using the tag database explorer. Make sure the controller is in “Rem Run”
mode.

72. The drive is configured to use speed units in Hertz. Enter a speed set point of 10 Hz. Place your cursor in
the value column for “PF755TS_CtrlSet.Speed”, enter a value of 10.0 and press the “Enter” key on your
keyboard. This is the speed the drive will be commanded to run.
73. Place your cursor in the value column for “PF755TS_CtrlCmd.ResetFault”, enter a value of 1, and press
the “Enter” key on your keyboard to clear any faults that may be present. After a second or two, the value
should change back to 0 indicating that it has completed executing the reset command.
74. Place your cursor in the value column for “PF755TS_CtrlCmd.Activate”, enter a value of 1, and press the
“Enter” key on your keyboard to start the drive. After a second or two, the value should change back to 0
indicating that it has completed executing the start command.
75. Monitor the value in “PF755TS_CtrlSts.Speed”. You should see the value ramp up 10. Since we are
using an encoder for closed loop velocity control, the feedback will be constantly changing by very small
amounts as the velocity loop works to minimize error. Verify that the motor is spinning.

76. Place your cursor in the value column for “PF755TS_CtrlCmd.Deactivate”, enter a value of 1, and press
the “Enter” key on your keyboard to stop the drive. After a second or two, the value should change back to
0 indicating that it has completed executing the stop command.
77. Monitor the value in “PF755TS_CtrlSts.Speed”. You should see the value ramp back down to 0. Verify
that the motor has stopped spinning.
78. Although the Add-On-Instructions are slightly different for each drive platform to accommodate the
differences in the product, the tags you use to interface with the instructions are identical. This allows you to
write application logic that is product independent and use it for a variety of drives. Take a few minutes to
try it for yourself. Repeat the same steps for the PowerFlex 525 drive and see if you can run it at 35 Hz.
Hint: You will need to open the Parameters and Local Tags for “EM01_PF525”.
Rockwell Automation produces and maintains application code for common applications. The code is part of
Machine Builders Library which can be downloaded from the Rockwell Automation Product and Compatibility
Download Center. The Automation Device Object logic was designed to work with the Machine Builders
Library Code.
Faceplate
79. If not already running, use what you learned in the previous section to configure the panelview to run
“PowerFlex_Lab.VPD”.

80. On the main screen, click on the “PowerFlex 755TS” button to open the PowerFlex 755T
drive faceplate.
Before continuing, take a minute to review the information available on the Home screen.
81. Notice how the Jog Setpoint and Jog Pushbuttons are “greyed” out. The ADO allows for disabling the
manual controls on the Faceplate. In this implementation, the controls are disabled unless the system is
placed in “Manual” mode and the system is in the “Execute” state.
The program has been configured using 3 modes of operation. Production mode is full functionality with
product sensors as required. Maintenance mode is full functionality but bypasses any product sensors to
allow the system to be run without product. Manual mode allows the individual drives to be jogged from the
HMI. All three modes require the system to be in the Execute State before it allows the drives to run.
82. To place the system into Manual mode, close the faceplate and click the “Left Arrow” on the middle
right side of the main screen to show the hidden panel.

83. Click the “Operating Mode” button located on the top left of the panel to open the operating mode
popup screen.
84. Click on “Manual” to select the manual mode and then click the “X” to close the “Operating Mode” screen.
85. Click on the “Right Arrow” located on the middle left of the panel to hide the panel.
86. Using what you have learned previously, put the system into the “Execute” state.
87. On the main screen, click on the “PowerFlex 755TS” button to re-open the PowerFlex
755T drive faceplate.
88. Click in the white box beside “Jog Setpoint” to open the numeric keypad.

89. Enter a value of 35 Hz then click OK.
90. Notice that the Jog Setpoint value updated to reflect 35 Hz but the Commanded value did not. This is
because the Commanded value is being read from the controller setpoint unless one of the Jog Pushbuttons
is pressed.
91. Click and hold the “Jog Forward” button. Notice that the “Commanded” value updates and the gauge
updates to reflect the current speed and direction. Also notice that the Speed and Current trends show the
speed and current ramping up to a steady state non-zero value.
92. Release the “Jog Forward” button. The drive will stop and the Commanded value will return to the
setpoint in the controller.

93. Click and hold the “Jog Reverse” button. Notice that the speed is shown as a positive number but the
status indicator at the top of the gauge indicates that it is running in reverse.
94. Release the “Jog Reverse” button. The drive will stop as before.
95. Click on the “Trend” button to open the Trend screen. The top trend shows speed setpoint and actual
speed in Hz. The bottom trend shows current as percent of full load amps (%FLA). By default, the scaling
of both trends is 0 to 100. Many times, this scaling may not be appropriate for the application.
96. Click on the “Trend Configuration” button to open the “Trend Limits” screen.

97. Like you did when you set the “Jog Setpoint”, you click in the white boxes next to the Minimum and
Maximum for Speed and Current to open the keypad and change the values. Edit the values to match the
settings below.
98. Click on the “Trend” button to return to the Trend screen. Notice how the trends reflect the scaling you just
configured. If the configuration is not changed, the trends default to 0 for minimum and 100 for maximum.
99. Temporarily close the faceplate by clicking the “Close” button.
100. You are now going to put the system back into “Production” mode. Click the “Stop” button to place
the system into the “Stopped” state because the mode cannot be changed while in the “Execute” state.
101. Click the “Left Arrow” on the middle right side of the main screen to show the hidden panel.
102. Click the “Operating Mode” button located on the top left of the panel to open the operating mode
popup screen.
103. Click on “Production” to select the production mode and then click the “X” to close the “Operating Mode”
screen.

104. Click on the “Right Arrow” located on the middle left of the panel to hide the panel.
105. Using what you learned in the previous exercise, start the drives with the buttons on the left side of the main
screen.
106. Click on the “PowerFlex 755TS” button to re-open the faceplate.
107. Click on the Trend button to return to the trend screen. The pens on the trend should be updating.
108. Now click on the “Exceptions” button to open the faults and alarms screen. This screen shows the last
four events the drive has encountered with time stamp and in most cases a description. Whether it is a fault
or an alarm will be indicated in the “Severity” column.
Your drive may have different exceptions than the ones shown here. The faceplate pulls the time stamp from the controller.

109. Click on one of the exceptions that has a description.
This will open a screen that shows the exception details and provide some guidance on common causes and remedies.
110. Click to close the “Details” screen. If your drive has more than one exception with a description, click
on them to view their common causes and remedies.
111. When you are finished, click the “Close” button to close the faceplate.
112. Click the “Stop” button to stop the drives.
113. Close the PowerFlex_Lab project by clicking File and then Close.
114. If prompted to save the changes, click No.
The Drive Automation Device Objects include logic and HMI faceplates to provide a common control interface for different
model drives. This allows for standard code to be developed and deployed across a wide range of products. The Drive
ADOs are part of the Power Automation Device Objects which can be downloaded from the Rockwell Automation Product
Compatibility Download Center free of charge.

Lab 5: Trending in CCW
Starting with version 11, Connected Components Workbench software has the ability to trend drive data. Trending is a very
useful tool for troubleshooting drive applications.
Basic Setup and Operation

In this exercise you will perform the following:
 Connect to the PowerFlex 525 drive through the embedded EtherNet/IP via Connected Components Workbench software
and add it to a project.
 Connect to the PowerFlex 755TS drive through the embedded EtherNet/IP via Connected Components Workbench
software and add it to a project.
 Create a Basic trend with values from both the PowerFlex 525 and PowerFlex 755TS.
 Start the trend and explore basic settings
Preparing the System
1. Start the Studio 5000 program. Double-click the Studio 5000 software icon on the desktop.

2. A pre-configured Studio 5000 Logix Designer software project has already been created for your
convenience. From the splash screen, click “Existing Project” under the “Open” column.
3. Select the “PowerFlex_Lab.ACD” file and click the “Open” button. If using a v2 755TS demobox (755TS
drive without 20-750-S4) use the file “PowerFlex_Labv2.ACD”.
Lab files are located within the “C:\Users\labuser\Desktop\Lab Files\PowerFlex Lab” folder.

“192.168.1.32, 5069-L3100ERMS2” via the AB_ETH-1 Ethernet driver is selected and click the “Go Online”
button.
6. If prompted to either Upload or Download, choose “Download” and continue with the next step.
If it goes online without the prompt, skip to step 9.

9. Look at the I/O Configuration and verify that the PowerFlex 525 connection is inhibited. This is indicated by
the Yellow circle with the pause symbol on the module. If it is inhibited, skip to step 12. If it is not inhibited,
proceed with the next step.
The PowerFlex 525 only allows one connection at a time. In order to create a trend for the first time, the
ControlLogix connection must be inhibited to allow CCW to connect. Once the Trend project has been
created, the trend can be run and edited without requiring the connection to be inhibited. The PowerFlex
755TS allows multiple connections and therefore does not have the same requirement.

PF525_Drive”.
11. Click on “Connection” to open the connection category. Click in the box beside “Inhibit Module” to
place a checkmark in the box. Click OK when complete.
Adding Drives to a Project
13. On the computer’s desktop, double click the shortcut for Connected Components Workbench software.

15. For trending to work, you must be connected to a drive and it must be a device in the active project. Click
Discover to go online with the PowerFlex 525 drive.

PowerFlex 525” device.
status window.
the top of the PowerFlex 525 window to indicate you are online with the drive.

18. Click Add to Project to upload all parameters and add the drive to the active project.
19. For a brief moment, you will see a status bar while the parameters are being uploaded.
20. When the upload completes, the drive will appear in the Project Organizer.
21. Click the Discover button in the project organizer and repeat steps 15-19 to add the PowerFlex 755TS to
the Project Organizer.

Having the drives in the Project Organizer is a requirement for adding traces for their parameters. If they are
not there, the process for adding them is to simply connect and then click the Add to Project button. Drives
can also be added to the project offline but must be connected when running the trend for the values to
update.
Create the Trend and add Traces
22. Click on the “Trends” tab.
23. Click the “Add Trend” button to open a new trend window.

24. In the Trend window, make sure TRACES is selected and click the [+] sign to open the Add Trace dialogue.
Selection of TRACES, SAMPLING, or TRIGGER is indicated by the light blue bar under the heading.
25. Click on [>] beside the PowerFlex 525 drive to drill down into the parameters.

26. Continue to click the [>] until you reach the Basic Display parameters. The progression is PowerFlex 525_1
> Port 0 – PowerFlex 525 > Parameters > Basic Display >. When complete, the following window will
appear.
27. Click in the boxes next to Output Freq, Commanded Freq, and Output Current to select them as traces.
When finished making the selections, click “ADD” to add them to the trend.

28. This should return you to the Trend Properties window. The parameters you selected should appear in the
window. Click anywhere on the bar (except for the Trash Can) for “PowerFlex 525_1: Port 0. 1 – Output
Freq” to open the trace properties.
Clicking on the Trash Can will permanently remove the trace from the trend. If deleted, it can be re-
added in the Add Traces dialogue.
29. From here, we can configure the trace minimum and maximum for the Y-axis of the trend. Double click on
the values to select them and change the Axis min and Axis max value to match the figure below.

30. Repeat the process to change the Min and Max values for Commanded Freq and Output Current. Set the
Commanded Freq to -60 min and 60 max. Set the Output Current to 0 min and 2 max.
31. With CCW Trend, you can add traces from multiple devices. Click the [+] sign to open the Add Traces
dialogue and follow the same procedure to add traces for the PowerFlex 755TS. Add Output Frequency,
Output Current, and VRef Commanded. The progression is PowerFlex 755T_1 > Port 10 – Induction FV >
Monitor > Metering >.
32. After you have added the traces, configure their min and max values. Set the Output Frequency and
Commanded SpdRef to -60 min and 60 max. Set the Output Current to 0 min and 2 max.
33. Now select SAMPLING. This is where you configure how often samples are collected (Sample rate) and
how many samples are collected (Capture size). For now, you will do a simple time based capture for 2
minutes of data. Configure SAMPLING as shown below.

34. Finally select TRIGGER. When the trend is running, it is continually collecting data at the sample rate. The
trigger is used to let the application know when to start plotting the traces. For now leave the trigger Type at
the default setting of Manual. This will allow the data to be plotted as soon as the trend is started. Also
leave the “Allow overflow” option checked so that the trend will continuously run and plot the most recent 2
minutes worth of values. You will have an opportunity to try other trigger settings later in the lab. Click OK
to close the Properties window and display the actual trend.
35. Take a couple minutes to review the main areas of the trend. In time, you will explore them all. When
finished, click on the Play button to start capturing data.

36. Observe how the countdown timer starts counting. Also observe that the Play button changed to a Stop
button. Notice that each trace has its own individual y-axis. You can use the slider on the right to scroll up
and down to see the remaining traces. This is the default setting for the trend and is called “Stacked”
because each trend is stacked on top of the other. Click the Gear in the trend settings portion of the screen
to open the Display Settings.
37. There are two settings that can be adjusted in the Display Settings popup. These are Y-axis and Scaling.
By default, the scaling is set to Automatic. Click the Down Arrow for Scaling to reveal the options of
Automatic and Manual. When in Manual, the y-axis scaling is set by the Min and Max values configured for
each trace. When in Automatic, the scaling is continually adjusted to accommodate the minimum and
maximum values observed for the configured capture time (in our case 2 minutes). Because the drives are
not currently running, the traces are all showing 0 for their values and the min and max scaling values are
not shown because there is not any min or max data. Click Manual to change the scaling to manual.

38. Notice that the Min and Max scaling values have changed to the values configured for each trace earlier in
this exercise. Now click the Down Arrow for Y-axis to reveal its options. You have already observed the
default Stacked. Click on Single to see how it looks.
39. When Single is selected, all traces are plotted on a single y-axis with a single min and max scaling. Notice
that the scaling changed to Automatic and is “greyed” out. The reason for this is that the scaling has to be
automatic. The minimum and maximum for all traces are evaluated and the absolute minimums and
maximums are used. Now change the Y-axis to Overlaid.

40. When Overlaid is selected, each trace is plotted on its own y-axis and is scaled individually. The y-axes are
literally on top of one another. The scaling values shown on the trend can be set to any of the configured
traces by clicking on the trace in the legend and then clicking on Select. Initially the scaling values are not
shown until you make a selection. Try it out by clicking on the Output Frequency trace for the PowerFlex
755T in the legend and then click Select.
41. The light blue bar under the trace indicates which values are being shown for the Y-axis scaling. The color
for the scaling also changes to match the color of the trace. All of the traces are still being scaled
individually and do not adjust to the values being displayed. At any time, you can select another trace to
show its scaling. Try selecting Output Current for the PowerFlex 525.

42. You can also remove the scale by clicking on the active trace and then clicking “Deselect”. Go ahead and
remove the scale by clicking Output Current for the PowerFlex 525 and then click Deselect.
By this time, you should have noticed that the countdown timer is flashing 00:00:00. This is an indication that
the trend has captured data for the full 2 minute sample time. When this occurs, new data is still being
added to the right side of the trend while the older data is being pushed out on the left.
Trending in CCW is simple to use yet powerful tool for troubleshooting. Traces for multiple devices can be added to the
trend from the parameter browser as long as the device is part of the project. Trend has multiple views and scaling options
to display the information in the format needed.

Advanced Setup and Operation
For this exercise, you will run the drives so that you can see changing data. In this section you will perform the following:
• Adjust the viewing area for the trend.
• Place a cursor on the trend to view the actual values at that point.
• Place the “delta” cursor on the trend to view the values at that point as well as the change in value from the
first cursor placed.
• Remove the cursors from the trend.
• View the effects of the different trigger types.
Start the drives
43. Minimize CCW so that the desktop is visible.
44. Open the “Lab Files\PowerFlex Lab” folder on the desktop, and open the “PowerFlex_Lab.VPD” file.

Download
48. Wait for the process to complete before proceeding to the next step. When complete, you will see the
following on the panelview.

49. Click on the I/O button on the banner.
50. From the I/O window, click on the PF525 Connection and PF755TS Connection selector switches to
uninhibit both the PowerFlex 525 and PowerFlex 755.
51. Click on the Home button on the banner to return to the main screen.

52. To clear the faults after downloading the program, press the “Clear” button.
53. The ribbon at the top will now read “Machine Healthy” instead of “Machine Faulted”. Press the “Reset”
button to reset the system.
54. The system is now in the “Idle” state. Press the “Start” button to start both drives.

55. Verify that the state is “Execute” and both motors are rotating.
Customize the view
56. Minimize View Designer and return to CCW. Let the drives run through a couple cycles before continuing.

57. In the View Settings, there are two preset views, VIEW LATEST and VIEW ALL. When the Trend is started
and the Trigger Type is Manual, the view is defaulted to VIEW ALL which shows the full capture time. Click
VIEW LATEST to see last 10 seconds of data captured.
VIEW ALL shows all of the data captured up to the maximum sample size (2 minutes for this example). If the
trend had been stopped after only collecting 1 minute of data, VIEW ALL would have shown only 1 minutes
worth of data.
58. Stop the trend by clicking the Stop button.
59. In addition to the preset views, Trend also gives you the ability to customize the view. You can customize
how much of the capture is shown as well as where in the capture you want to focus. Click and hold the
Horizontal Slider Bar below the captured data. While holding, move the slider bar to the middle of the
capture. Release the slider bar when complete. This changes the view location.

You can also use the left and right arrows to reposition the view.
60. You can change the amount of data displayed by grabbing the left and right anchors and dragging them to
expand or reduce the view area. Click and hold the Left Anchor . Drag it to the left until one complete
cycle is shown.
61. At times, there may be too many traces on the screen to see what you want to see. You can temporarily
hide traces to remove some of the clutter. Click on the Output Frequency pen for the PowerFlex 755T and
then click Hide to remove the trace from the view.
Trend still captures data for hidden traces. Hiding it simply removes it from the plot.

62. Repeat the process and hide the other two PowerFlex 755T traces. Only the three PowerFlex 525 traces
should be visible now. You will also notice that the three PowerFlex 755T pens are “greyed” out.
63. To return the traces to the plot area, you need to click on the pen and then click Show. Go ahead and
return the PowerFlex 755T traces to the view.
Adjusting the view area or position on the trend allows you to zoom in or out to see the data as needed. Trend has two
predefined views but also provides the flexibility to customize the view to fit your needs.

Using cursors
64. Click anywhere in the plot area to place a cursor. Placing a cursor displays the values for each trace as well
as the time. The cursor is represented by a solid line.
When placing a cursor, if pointing at a trace, the data point will highlight to assist with accurate placement.
65. Now click in a different location in the plot area to place the delta cursor. The delta cursor display the same
information as the cursor but in addition also shows the change in value (or the delta Δ) for the traces and
time. The delta cursor is represented by a dashed line.
Once the cursor is placed, continuing to click in the plot area places the delta cursor. If the delta cursor was
already placed, it will relocate it to the new position. This allows you to compare multiple locations in the plot
to the original cursor location.

66. If you want to move the cursor, you must first remove (unpin) the currently placed cursor(s). Click the
Unpin button to remove the cursors. You should now be capable of re-positioning the cursor to another
area of interest.
67. If something of interest is found that you want to share with others, you can print the current plot with the
cursors in place. Click the Print button in the Main Menu. When the print dialogue appears select
Microsoft Print to PDF. Click Print when it is selected.
To print, data must have been captured and the trend must be stopped. The button is “greyed” out if either of
these conditions are not met.

68. Give the file a name and save it to the desktop.
69. Minimize CCW. Locate the file on the desktop and double click on it to open the file. You will see that what
was displayed in the trend is now in a PDF document that you can share. Your file will look different than
the one shown here.
If you see a symbol under the traces, this indicates that the drive was offline when the trend was printed.
Note: For this manual, the PDF document was rotated and fit to one page in Adobe Reader. Original
document was landscape.
70. Close the file and return to CCW.
71. Another way to share trend data is to export to a CSV file. Sharing a CSV file allows the data to be
analyzed by another software package capable of opening CSV files. Click the Export button.

72. When the Save as window appears, give the file a name and click Save to save it to the desktop.
73. Minimize CCW and verify that the file was saved to the desktop. This image does not include a software
package that would be useful in analyzing the data. If you want to see what information is available in the
file, you can open it with Notepad. Otherwise continue to the next step.
Cursors allow users to display data values at a specific location in the trend. Besides the main cursor, there is a delta
cursor that not only displays the value for that location but also shows the change in value from the originally placed cursor.
The cursors help convey information and are included when the trend is printed.
Trigger Modes
The trigger is a powerful feature that controls when the trend plots the traces. When running, Trend is continually collecting data
for all configured traces but the traces are not visible until the specified trigger condition is met. This is especially useful for
troubleshooting random problems. The trends can be started and will capture the data when the event occurs without requiring
the user to be constantly monitoring the trend to stop it manually.

74. To configure the Trigger, you have to return to the trend properties. There are two ways to accomplish this.
You can click on one of the trace pens and then click on Properties. You could also click the Properties
button in the Main Menu. For this exercise, use the latter. Click the Properties button in the Main
Menu.
75. When the Properties window opens, click the Trigger tab.
76. Now click the Down Arrow beside the Type to reveal the options. It is currently set for Manual.

77. When the Menu appears, select Analog.
78. You will notice that several more configuration items appear on the screen. The first is Trigger Source. The
trigger source is any parameter in the drive you want to monitor and use its value as a condition to start
trending. It does not have to be one of the traces in the trend. Click the Ellipsis button beside Trigger
Source to select the parameter.
When any trigger type other than manual is selected, the Allow Overflow setting is removed. These other
trigger types are used to capture events. If Allow Overflow was used for these types, the event you were
trying to capture could potentially be overwritten if you were not there to stop the trend at the appropriate
time. With the setting removed, you can start the trend and walk away. If the event occurs, the information
will be there when you return.
79. The Trigger source selection window should be visible. For this exercise, you are going to configure the
trigger so that it starts plotting when the output frequency for the PowerFlex 755T drive exceeds 45 Hz.
Type Output Frequency in the Filter field.

80. As you typed, you should have noticed parameters with that text in the name appear in the list. This is a
shortcut for selecting parameters when you know their name or parameter number. If neither is known, you
can still browse through like you did when adding traces. Click in the Circle to select the parameter. Click
SELECT when finished.
The Filter can also be used when adding traces to the trend if the parameters name or number is known.
81. The next item to configure is the comparison operator. By default it is set as Equal To (=). Click the Down
Arrow to reveal the choices and select Greater Than (>).
82. The Value field is defaulted to the parameters minimum value defined in the drive (-590 in this case). Click
in the value field and change it to 45 Hz. Make sure you remove the negative sign [-].

83. The Hysteresis value specifies how many consecutive samples the trigger condition has to be true before
the trend starts plotting. This is useful if the data fluctuates around the set point and you want to make sure
the condition is truly met. If left at the default of 0, the trigger will occur on the first sample the condition is
met. Click in the hysteresis field and change it to 2 Samples so that it requires two consecutive samples
with the value above 45 Hz.
Notice under the setting, the actual trigger delay is shown. For this example, two samples at a 50 ms sample
rate produces a 100 ms delay.
84. The last item to configure is Pre-sampling. When you start a trend, data is being collected even if the trigger
condition has not been met. The Pre-sampling setting allows you to specify how much data leading up to
the trigger event you want to display. The value is expressed in percent of the total sample time (2 minutes
in this exercise). The default is 0 and would only display data after the trigger condition was met. Click in
the Pre-sampling field and change the value to 25. This will display 30 seconds (25% of 2 minutes) of data
before the trigger condition was satisfied. Click OK when complete.
85. With the drives still running, click the Start Trending button to start the trend.

86. Remember, once the trend is started, it is collecting data. The screen will reflect that it is waiting on the
trigger condition to be met before plotting the data. It also shows the configured trigger condition.
87. When the condition is met, the trend will start plotting the data. A red vertical line is placed on the plot in the
location where the trigger condition was satisfied. You can see that it did in fact include data prior to the
condition being met.

88. The trend will automatically stop when the countdown timer expires. If you like, you can wait until the trend
stops on its own. If you are satisfied on how it works and want to proceed now, you can press the Stop
button at any time. The trend has to be stopped before the trigger settings can be changed. Feel free to
take a minute or two to review the trend. When finished, proceed to the next step. Remember, you can
change the view to VIEW ALL to see the whole capture.
89. Now try the Bit trigger type. Configure the trigger to occur when the PowerFlex 525 is Accelerating. Use
Rising Edge (transition from 0 to 1) with a Hysteresis of 2 and Pre-sampling of 20%. Click OK when
finished.
Bit trigger is commonly used to capture data leading up to a fault. In this case you would select the faulted
status bit as you trigger source.

90. Start the trend and confirm that the plot was started when the PowerFlex 525 started accelerating.
If you allowed the trend to automatically stop, you might have noticed that the pre-sample was not the full
time expected. This is because it is only collecting data while the trend is running. If the trigger condition is
satisfied before enough data has been collected to satisfy the Pre-sampling setting, the pre-sample area is
downsized. In this case, the pre-sample size will be the elapsed time from when the trend was started to
when the trigger condition was met.
91. The last option for the trigger is Time. The time based trigger allows you to specify a time of day to start the
plot. This is useful if something is occurring during a specific time period that you want to capture and you
are not sure what analog or bit trigger source to use. Return to the trigger settings and select Time for the
Type.

92. Look at the Windows clock in the bottom right of the screen. You are going to set the trigger time to be 3
minutes from the current time. Three minutes was chosen to give you enough time to finish the
configuration and start the trend. To change the time, individually click on the hours, minutes, seconds, and
AM/PM fields and enter the correct values. Set the Pre-sampling to 10%. Click OK when complete.
93. Start the trend. Confirm that the trigger occurs at the correct time.
Hint: Use the cursor to identify the location of the trigger line.

94. Minimize CCW and return to the panelview.
95. Press the “Stop” button to stop both drives.
Trend has several useful features to aid with troubleshooting.

 The ability to add traces for multiple devices on a single trend provides the ability to see interaction between the
devices.
 Customizable views allows for displaying the data in the appropriate format.
 Cursors to provide details about the traces at locations of interest.
 A full featured trigger function to allow the event of interest to be captured even if no one is present when it occurs.
Lab 6: Automatic Device Configuration (ADC) with the PowerFlex AC drives
About Automatic Device Configuration (ADC)

Automatic Device Configuration (ADC) is a feature (in Version 20 of RSLogix 5000 software and Version 21 or higher in Logix
Designer software) that supports the automatic download of configuration data. This occurs, if necessary, as the Logix controller
establishes an EtherNet/IP network connection to a PowerFlex drive, firmware revision 4.001 or later, and its associated
peripherals.
ADC will occur the first time the Logix controller connects to the drive after ADC is enabled. This is necessary
to ensure a configuration match, and to generate and write configuration signatures for each port. Future
connections made by the Logix controller, such as after a reset or power loss, will first check the
configuration signatures to determine if an ADC download is necessary
The project file and controller contain the configuration settings for any PowerFlex drives in the project. When the project is
downloaded to the controller, these settings are also transferred and reside in the controller’s memory. ADC automates the
process of downloading the configuration to the drive and saves you time. It is particularly beneficial in a drive replacement
situation where maintenance personal may not have access to laptops or workstations.
This feature is currently available for the following PowerFlex drives:

 PowerFlex 525 via Embedded Ethernet (EENET) and Dual Port Ethernet (E2P)
 PowerFlex 523 via Dual Port Ethernet (E2P)
 PowerFlex 755 (Version 4.001 and up) via Embedded Ethernet (EENET) and Dual Port Ethernet (ENETR)
 PowerFlex 753 (version 7.001 and up) via Dual Port Ethernet (ENETR)
 PowerFlex 755T via Embedded Ethernet
 PowerFlex 755TS Via Embedded Ethernet
ADC can also work in tandem with Firmware Supervisor. When Firmware Supervisor is set up and enabled in the project, and if
the respective ControlFLASH firmware kit is installed on the computer when the project is downloaded, the drive and peripherals
will be automatically brought to appropriate firmware revision if needed. This further reduces the need for maintenance personal
to access laptops and workstations while replacing drives.
The controller project owns the configuration of the drive. ADC will be triggered any time the controller
detects a configuration signature mismatch when establishing an EtherNet/IP network I/O connection.
The use of other configuration tools, such as a HIM or Connected Components Workbench software should
be minimized and restricted to monitor-only operation. Any configuration changes made by these tools will
cause a configuration signature mismatch the next time the Logix controller connects to the device and ADC
will write over any changes made by the other tool(s). Any drive configuration changes should be made with
the drive Add-On Profile.
With ADC configured properly, changing out a drive at 2:00 AM could be as simple as installing the new drive, connecting the
wiring, and powering up the system. The drive would receive its IP address from the BOOTP server (present on the local
industrial Ethernet switch) and if necessary, Firmware Supervisor would update the firmware to the required level. With the
firmware version and IP address being correct, ADC would then automatically configure the drive with the parameters required
by the application. This saves significant time and eliminates errors that could be present with traditional configuration methods.
This exercise will help teach you how to set up ADC for a drive. For more information in regards to the PowerFlex 525 drive and
Automatic Device Configuration (ADC), refer to the PowerFlex 525 Embedded EtherNet/IP Adapter User Manual. There is also
information about Automatic Device Configuration (ADC) in the PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter User
Manual.
Prepare the system for Automatic Device Configuration (ADC)
1. Open the “Lab Files\PowerFlex Lab” folder on the desktop.

2. Double click on the file named “PowerFlex_Lab.VPD” to open the View Designer application.
3. You may receive the following error when trying to open the file. Do not re-start the image. Simply click OK
to close the window and try opening the file again.

Download
Wait for the process to complete before proceeding to the next step. When complete, you will see the following on the
panelview.

Exploring the Setup of Automatic Device Configuration (ADC)
4. In Studio 5000 Logix Designer, click the “Open” icon illustrated below to select an existing project.
5. Select the “PowerFlex_Lab_ADC.ACD” file and click the “Open” button. If using a v2 755TS demo box
(755TS drive without 20-750-S4) use the file “PowerFlex_Labv2.ACD”.
Lab files are located within the “C:\PowerFlex Lab” folder.

PF525_Drive”.
7. Just above the button labeled “Device Definition” notice that there is some grayed out text that says “ADC
Disabled”. Click on the button labeled “Device Definition”.
The Device Definition window will appear. The drive AOP requires deliberate action to enable ADC. This helps ensure that
ADC is fully understood prior to turning it on.
8. Click on the “Automatic Device Configuration” category.
This will open the Automatic Device Configuration setup window.

9. The picture below shows how to enable or disable ADC for the PowerFlex 525 drive and its peripherals (if
applicable). Click the check box that is highlighted below to enable ADC. That’s all it requires to enable this
time saving feature.
10. Click the “OK” button in the Device Definition window to accept the changes and close the window.
In order for setting changes to take effect, you must click the “OK” button before closing the window with the
[X] at the top corner.
11. A window will appear asking you to confirm the module definition change. Click “Yes” to accept the
changes.
12. Notice that the text above the “Device Definition” button turned green and now says “ADC Enabled”. Click
the “OK” button to close the Module Properties window.

13. Repeat steps 6-12 for the “PowerFlex 755T PF755TS_Drive”.
After clicking the checkbox to Enable Automatic Device Configuration the following message will appear. For this lab click
“Maintain”.

“192.168.1.32, 5069-L3100ERMS2 via the AB_ETH-1 Ethernet driver is selected and click the “Download”
button.


17. When prompted to confirm switching the controller back to “Remote Run”, click the “Yes” button.
18. Automatic Device Configuration (ADC) may cause the transition to run to be longer. If the following window
appears, click the “OK” button to acknowledge the delay.
Setting up ACD, in most cases, is as simple as checking a single box. Some applications, such as those with Integrated
Safety, do require that the ports be enabled individually but even then, this powerful time saving feature can be enabled with
minimal configuration.
Demonstrating Automatic Device Configuration

In this section, you will generate a configuration mismatch by changing a parameter on the drive and then reconnecting it. This
will cause the ADC feature to activate and restore the drive to its programmed configuration.
19. Wait for the drive to be configured from the previous download. That will be indicated in Logix Designer by
the following transition:
* This could take a couple of minutes

** If you are viewing the HMI screen, the Connection Status indicator will alternate between “Faulted,
Configuring, and Shutdown”
21. Return to View Designer Emulate.
22. Press the I/O button on the banner.

23. Inhibit the PowerFlex 525 drive to break the connection between the controller and drive. This will generate
a fault on the drive.
24. Using Connected Components Workbench (CCW) and what you learned in previous exercises, change
parameter “P033 – Motor OL Current” in the PowerFlex 525 to 1.0 (or another value if you desire). This is
being done to create a parameter mismatch between what is in the controller and what is in the drive.
25. Close CCW after changing the parameter.
26. Uninhibit the PowerFlex 525 to reinitiate communication between the drive and the controller. This will
initiate the controller verifying the configuration signature of the drive and force a reconfiguration if there is a
mismatch.
Notice that the PowerFlex 525 drive will get a F048 – Parameters Defaulted fault after a few seconds. This is normal and
the first step of the Automatic Device Configuration process. The drive is now being configured.
27. Go back to the I/O Configuration tree in Logix Designer; you will notice a Yellow triangle next to the
PowerFlex 525 drive (PF525_Drive). Click once on the drive to highlight/select it.
28. On the HMI Touch the Home button on the banner to return to the main screen.

29. On the Main screen of the HMI, there is a multistate indicator which shows the connection status of the
PowerFlex 525 drive.
It will take a little time for the PowerFlex 525 drive to be configured.
30. Wait until the ADC process has completed. This will be indicated by the drive’s connection status switching
from “Configuring” to “Running”. Once this occurs, continue to the next step.
ADC will automatically reset (power cycle) the drive as part of the configuration process. This is done
because some parameters require a reset before they take effect. If a drive is being replaced with an out-of-
the-box drive, you will typically see one or more resets during the ADC process.
31. You can verify that the drive has the correct parameter now loaded for “P033 – Motor OL Current” through
the Add-On Profile using techniques you learned earlier this lab.

32. Verify that the drives still run. If the machine is currently in the ABORTED state, press the “Clear”
button.
After a few moments the state machine should transition to the STOPPED state.
33. Press the “Reset” button until to initialize the application. When initialization is complete, the state
machine should transition to the IDLE state.
34. Press the “Start” button. The system will transition to EXECUTE and begin operating according to
the Studio 5000 Logix Designer program.
The same logic from the previous section will be executed.
35. Press the “Stop” button. This will stop operation and transition the system back to the STOPPED
state.
ADC is a powerful, time saving feature. Not only will it automatically configure a replacement drive but will also reconfigure
a drive that has had parameters modified outside of Logix. This is extremely useful in the event that changes were made
that adversely impact operation. Simply break the Ethernet connection between the drive and controller and it will be
reconfigured with the project parameters when the connection is re-established.

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Drive Headquarters

Drive Configuration and

Identifies information about practices or circumstances

Lab 1: Connected Components Workbench (CCW) Overview ..................................................................... 7

Lab 2: Configuring the PowerFlex 525 AC Drive ........................................................................................ 30

Lab 3: Configuring the PowerFlex 755TS AC Drive ................................................................................... 50

Lab 4: Drives Integration into Logix Designer ............................................................................................. 74

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Lab 5: Trending in CCW............................................................................................................................ 108

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Please review the following information before starting this lab.

About this lab

Tools & prerequisites

Software programs required

Hardware devices featured

Lab files are located within the “C:\PowerFlex Lab” folder.

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Network Setup Ethernet Connections

IP address of 755TS configured with switches. 1 PC L3100ERMS2 Port 1

2 L3100ERMS2 Port 2 PV5510 Ethernet Port 1

3 PV5510 Ethernet Port 2 AENTR Ethernet Port 1

4 AENTR Ethernet Port 2 PF755TS Ethernet Port 1

5 PF755TS Ethernet Port 2 PF525 Ethernet Port

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About Connected Components Workbench™ Software.

Preparing the demo

1. Double-click the Studio 5000 software icon on the desktop.

You will see the following splash screen.

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The Who Active window will appear.

The Download window will appear.

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11. In the pop up warning click YES.

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Opening and downloading an existing offline CCW project.

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You may need to maximize the window to make viewing easier.

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5. Click on “PowerFlex_Lab” to highlight the file, then click Open.

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13. If the Synchronize – Merge window appears, click “Reset”.

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Adding a device to a project and uploading.

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Uploading and Saving the Drive’s Configuration to a PC

29. On the Start Page, click Discover.

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35. Give a name to your file and save on the desktop.

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37. Click OK to close the Device Definition window.

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