Rockwell Automation PowerFlex 525 Configuration Download

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PowerFlex® Drives Configuration & Programming

PowerFlex 525 & PowerFlex 755 AC Drives

For Classroom Use Only!

Summary of Contents for PowerFlex 525

Page 1: ...PowerFlex Drives Configuration Programming PowerFlex 525 PowerFlex 755 AC Drives For Classroom Use Only ...

Page 2: ... Documentation Except as specifically agreed in writing as part of a maintenance or support contract equipment users are responsible for properly using calibrating operating monitoring and maintaining all Products consistent with all Rockwell Automation or third party provided instructions warnings recommendations and documentation ensuring that only properly trained personnel use operate and main...

Page 3: ...d Components Workbench Software 53 Lab 3 PowerFlex Drives Add On Profile with Drives and Motion Accelerator Toolkit 81 About Integrated Drive Profiles and Premier Integration 81 Exploring the Add On Profile for the PowerFlex 525 Drive 82 Taking Advantage of Having the Drive in the Controller Organizer 91 Downloading the Project 94 About Drives and Motion Accelerator Toolkit DMAT 101 Switch to the ...

Page 4: ...outine Overview 123 Machine Module 124 Machine States 124 Machine State Diagram 125 Default Machine States 126 Default Machine Commands 126 Machine Control Module Tags 127 Machine Tags 127 Device and Application Status Rungs and Logix 127 Application Modules 131 Device Module Control Logic 135 Notes 136 ...

Page 5: ...ompactLogix controllers and other Allen Bradley products In that exercise you will see how to save time and money during system development operation and maintenance If you have extra time learn about the new Automatic Device Configuration ADC feature for PowerFlex 750 Series and PowerFlex 520 Series drives in Studio 5000 Lab layout This PowerFlex lab is broken into sections to allow user to choos...

Page 6: ...rdware devices required PowerFlex 525 527 Demo Box PF52X1 o CompactLogix 5370 Controller 1769 L18ERM BB1B v28 011 20 o 1738 ETAP o PowerFlex 525 AC Drive 25B V2P5N104 v4 001 with 25 COMM E2P Option module PowerFlex 755 DHQ Demo Box PN 39023 o PowerFlex 755 AC Drive 20G11 N B DM1AA6K32V8 v12 001 Ethernet patch cables Files required PowerFlex_Lab ACD PowerFlex_Lab_ADC ACD PowerFlex mer Lab files are...

Page 7: ... The PowerFlex 525 Network Option module IP address will be set using the Keypad in Lab 1 Hundreds 0 Tens 3 Ones 0 Ethernet Connections 1 PC L18ERM Port 1 front 2 L18ERM Port 2 rear ETAP Port 1 front 3 ETAP Port 2 rear PF525 25 COMM E2P Ethernet Port 1 4 ETAP Device Port front PF755 Embedded Ethernet Port ...

Page 8: ...8 of 136 About the PowerFlex 525 Demo Box ...

Page 9: ...9 of 136 About the PowerFlex 755 DHQ Demo Box ...

Page 10: ...rs Information The PowerFlex 525 drive is easy to configure with flexibility in programming options to meet your application One of these options is the Liquid Crystal Display LCD Human Interface Module HIM Some of its key features are as follows Improved visibility Increased resolution Descriptive scrolling text Three adjustable speeds Full alphanumeric characters with 5 digits and 16 segments Su...

Page 11: ... together for the following applications Conveyor Mixer Compressor Centrifugal Pump Blower Extruder Positioning Textile Fiber CustomView Parameter Groups can be customized specifically for your application Add up to 100 parameters Save new CustomView groups for easy copy and paste ...

Page 12: ...12 of 136 Control and Navigation Keys ...

Page 13: ...d Editing Parameters The following is an example of basic integral keypad and display functions This example provides basic navigation instructions and illustrates how to program a parameter Just read through the following ...

Page 14: ...the lab 1 Make sure DI1 is in the Left position 2 Make sure the CompactLogix controller is NOT in Run Mode If the RUN LED on the controller is lit move the switch to PROG bottom down position then REM position middle You may need to open the door on the controllor to access the switch ...

Page 15: ...ameter in that group will flash 7 Use the Up or Down arrows until you see P053 If you wait one 1 second you will notice that the HIM display scrolls with P053 Reset to Defaults Note Rather than pressing the Up and Down arrows to scroll through many parameters in numerical order you can also press Sel button to move from digit to digit or bit to bit The digit or bit that you can change will flash 8...

Page 16: ... the Network Option parameters starting at parameter N1004 N1004 Net Addr Sel 1 Parameters N1006 IP Addr Cfg 1 192 N1007 IP Addr Cfg 2 168 N1008 IP Addr Cfg 3 1 N1009 IP Addr Cfg 4 20 N1010 Subnet Cfg 1 255 N1011 Subnet Cfg 2 255 N1012 Subnet Cfg 3 255 N1013 Subnet Cfg 4 0 N1014 Gateway Cfg 1 192 N1015 Gateway Cfg 2 168 N1016 Gateway Cfg 3 1 N1017 Gateway Cfg 4 1 2 In order for communication setti...

Page 17: ...tions In this section you will perform the following 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 1 Go to the computer s desktop and double click the shortcut for Connected Components Workbench sof...

Page 18: ...the software to make viewing easier 3 There are many features in the Connected Components Workbench software Mainly we will be using the software to go online with the PowerFlex 525 drive Click the next to Discover within the Device Toolbox 4 Click the Browse Connections button to launch the RSWho connection browser ...

Page 19: ...owerFlex 525 1P 110V 50HP device 6 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 highlighted Connected for the PowerFlex 525 drive within the Connected Components Workbench software ...

Page 20: ...o view the PowerFlex 525 drive parameters as seen below The PowerFlex 525 drive 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 ...

Page 21: ... the non default parameters 5 Close the Port 0 Parameters dialog box by clicking 6 You can do the same with the option modules Select the select the 25 COMM E2P tab then click Parameters When the Port 2 Parameters dialog box opens click Show Non Default button Take a look you will notice that the parameters you changed in Part 1 appear in this list 7 Click the Show All button to return to viewing ...

Page 22: ... 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 Dig Speed or 10 and see the results Remember to clear delete the entry field when finished ...

Page 23: ... 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 ...

Page 24: ...ction box select the AppView parameter group for Conveyor Scroll through these application specific parameters 2 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 Edi...

Page 25: ...tor 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...

Page 26: ...by clicking the in the top right corner of the window PowerFlex 525 Drive Start Up Wizard 1 Click on the Wizards button The Available Wizards selection box will appear 2 Select the PowerFlex 525 Startup Wizard from the list and click the Select button to launch the PowerFlex 525 Startup Wizard After a moment the Welcome screeen for the PowerFlex 525 Startup Wizard will appear ...

Page 27: ... a few different options 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 Click the Reset button for the first option Reset all settings to factory defaults but retain the custom parameter group ...

Page 28: ...ay make a noise as it resets to defaults and then will display the F048 Params Defaulted fault on the HIM After you see the following indicator on the Startup Wizard continue by clicking the Next button 6 Make sure English is selected in the Language dropdown selection box and Click the Next button to proceed to the next page ...

Page 29: ...nd 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 ...

Page 30: ...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 ...

Page 31: ...umbered 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 ...

Page 32: ...veral 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 Control EtherNet IP ...

Page 33: ...x 525 terminal block The demo box switches will be assigned to Start Source 2 and enabled using switch DI1 Use the Start Source 2 pulldown menu to select Digin TrmBlk The demo box STOP START FWD DIR REV and DI1 switches are wired to terminal blocks 1 2 3 and 5 respectively Use the DigIn TermBlk 02 03 05 pulldown menus to assign these devices as shown below ...

Page 34: ...34 of 136 Relay Outputs changes required Opto Outputs Analog Outputs ...

Page 35: ...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 ...

Page 36: ...e OK button 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 its normal state 14 Disconnect connection to the drive You may be prompted to upload parameters from the drive or to save the project when exiting the Connected Components Workbench software Sele...

Page 37: ...e varies the speed and stops the drive 19 Move selector switch DI1 to the right position to enable Start Source 2 previously configured to use the PF525 DRIVE demo box switches 20 With the PF525 DRIVE switches toggle to start the drive reverses the direction and To stop the drive The Keypad Speed Pot still controls the speed 21 Use the push button or Keypad to stop the drive Continue on to the nex...

Page 38: ... feedback device and speed limits Perform a direction test Configure speed references ramp rates inputs and outputs Configure several parameters Information This hands on lab will provide you with an opportunity to explore the PowerFlex 755 AC drive The image below shows some of the essential keys which you will be using in this session Please familiarize yourself with these keys buttons One of th...

Page 39: ...eypad shown circled in the left image below Pressing the Folders button changes the HIM screen display to the Folders screen shown below to the right Depending on your drive configuration the text next to each number may vary Resetting Factory Defaults and Starting Wizard 3 Highlight Port 0 and use the left or right arrow keys to scroll through the different folders to locate the folder called MEM...

Page 40: ... located in the center of the HIM keypad to make this your selection ESC INFO Port 00 Set Defaults Host and Ports Preferred This Port Only 6 Use the soft key labeled ALL to reset default all parameter settings in the Drive W A R N I N G Use MOST to reset typical settings on this port preferred Use ALL to reset all settings ALL MOST 7 Use the CLR soft key to acknowledge and clear the Module Default...

Page 41: ...ghted by default Press the Enter key located in the center of the HIM keypad to make this your selection 11 The startup routine starts with an Introduction screen Press the ENTER soft key to continue The ENTER soft key is located on the top row of the HIM keypad PowerFlex 755 Startup Start Up consists of several steps to configure the drive Press ENTER ABORT ENTER Note You can always use the ESC s...

Page 42: ...Startup Setting the Motor Control Mode 13 Pressing the ENTER soft key in the previous step has led you to the General Startup Main Menu You will go through steps listed in this menu to configure your drive Press ENTER soft key to enter the first section Motor Control ABORT ENTER General Startup Motor Control Motor Data Feedback Main Menu Limits Complete these steps in order 14 The introduction scr...

Page 43: ... Startup Main Menu Motor Data should be highlighted now Press the ENTER soft key to make this your selection The next few steps will require you to input the nameplate information of the motor you are doing a Startup on ABORT ENTER General Startup Motor Control Motor Data Feedback Main Menu Limits Complete these steps in order 17 Pressing the ENTER soft key in the previous step has led you to the ...

Page 44: ...Nameplate NP Power The motor internal to the demo is rated 25 Watts 0 025 kW or 0 033 HP Notice that there are no designated buttons on the HIM keypad for entering a decimal point The PowerFlex 755 HIM keypad uses a soft key to provide a decimal point button This decimal point soft key is activated when the first digit in the numeric value is entered In this case start by entering 0 Notice how one...

Page 45: ...e Motor Nameplate NP RPM The Motor in the demo is rated for 1600 RPM Use the appropriate number keys to input a value of 1600 Press the ENTER soft key to confirm your input and move to the next screen 23 You should now be in the Edit Mtr OL Factor screen This screen allows you to enter the Motor Overload factor By default this parameter value is set to a value of 1 00 We will use this as our selec...

Page 46: ...nd other information required in the Motor Data section Pressing the ENTER soft key in the previous step has directed you to the Main Menu and the item Feedback should be highlighted Press the ENTER soft key to make this your selection ABORT ENTER General Startup Motor Control Motor Data Main Menu Limits Complete these steps in order Feedback 27 Select Open Loop as we do not have an encoder on boa...

Page 47: ...red you will be exited out of this section Max Fwd Speed 1600 RPM Max Rev Speed 1600 00 RPM you can directly enter a value of 1600 the negative sign is defaulted Min Fwd Speed 0 00 RPM Min Rev Speed 0 00 RPM Direction Auto Tune and Inertia Tests 30 You should now have been directed back to the General Startup Main Menu The Tests section is next and should be highlighted by default at this stage Pr...

Page 48: ...irection of rotation forward 33 The next screen asks the question How would you like to fix motor polarity Select the default highlighted option Automatic change by using the ENTER soft key Startup Direction Test Change fbk wires How would you like to fix the motor polarity Automatic Change 34 The screen that follows asks you to stop the drive so this change in direction initiated in the previous ...

Page 49: ...rity 38 Press the START button to begin the test and review changed motor direction 39 Select Yes as your answer when asked the question again Is the direction of rotation forward Startup Direction Test Is the direction of rotation forward No Yes 40 Press the Stop key This should successfully complete the Direction test 41 You should now be back in the Motor Test Menu screen Now use the ENTER soft...

Page 50: ...tor Test Menu screen Configuring the Speed Reference and Ramp rates 46 At this time you should be in the General Startup Main Menu The next item on the Startup menu list Ref Ramp Stop should be highlighted by default Press the ENTER soft key to make this your selection 47 The Edit Direction Mode box should be on the screen now We will use the default parameter value of Unipolar for this lab sessio...

Page 51: ...ate number key to enter a value of 3 seconds Press the ENTER soft key 57 Similarly enter a value of 3 seconds for the deceleration time in the Edit Decel Time 1 screen Press the ENTER soft key 58 The next screen continues the ramp speed configuration and asks the question Do you want to perform S curve for Accel Decel We will select No as the answer for this lab session You can select No by highli...

Page 52: ...oft key to make this your selection 70 Select the Anlg In0 Value 71 In the next page that comes up select Voltage for Analog Out 0 type 72 Set the Anlg Out0 DataHi to 10 0 volts and set the Anlg Out0 DataLo to 0 0 volts 73 Repeat for Anlg Out0 Hi and Anlg Out0 Lo 74 Press the ENTER soft key to select Disabled for the Anlg Out1 Sel 75 You should now be back in the Start Stop I O menu screen This is...

Page 53: ...twork connectivity options In this section you will perform the following Connect to the PowerFlex 755 drive through the embedded EtherNet IP via Connected Components Workbench software Explore the different parameter groupings Explore the Startup Wizard Connecting to the Drive 7 Go to the computer s desktop and double click the shortcut for Connected Components Workbench software You will see the...

Page 54: ...the software to make viewing easier 9 There are many features in the Connected Components Workbench software Mainly we will be using the software to go online with the PowerFlex 755 drive Click the next to Discover within the Device Toolbox 10 Click the Browse Connections button to launch the RSWho connection browser ...

Page 55: ...werFlex 755 PowerFlex 755 device 12 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 highlighted Connected for the PowerFlex 755 drive within the Connected Components Workbench software ...

Page 56: ...Take some time to explore them 14 Select the Process Display The Process Display allows you to view parameter values in an easy to read graphical display 15 Navigate back to the Process Display and click on the Pencil icon for the middle display item In this window you can select scale and assign text to Display Item 1 In this lab we will leave the parameter as is Close the Process Display window ...

Page 57: ...ision and operational status Your Demo has only peripherals 0 1 and 7 Take some time to explore them 17 You can display the status view for any peripheral e g the DeviceLogix adaptor or 20 HIM x6 by selecting the peripheral s tab If your demo box does not include the stated cards use the available tabs and explore the peripherals on your demo 18 After checking peripherals 0 1 and 7 return to perip...

Page 58: ...eters as seen below The PowerFlex 755 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 You can scroll down to Parameter 11 DC Bus Volts Double click on this parameter to view it ...

Page 59: ...NP RPM according to the setting in Parameter 300 Speed Units To edit this parameter a new value would be entered followed by clicking OK In this case though click Cancel Similar to PowerFlex 525 the PowerFlex 755 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 wer...

Page 60: ...A progress window showing the upload will appear 21 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 parameters you changed in Part 1 appear in this list 22 Click the Show All button to return to viewing all of the PowerFlex 755 drive parameters ...

Page 61: ...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 inp torque or 535 and see the results Remember to clear delete the entry field when finished ...

Page 62: ...p Rates from the Speed Control Group dropdown menu and explore the parameters shown below You ve just seen some of the parameters needed to start up commission a PowerFlex 755 drive Take some time to explore some of the other parameter groupings such as Feedback I O Applications Communication and Diagnostics 26 Close the parameters ...

Page 63: ... series and revision is 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 Some additional wizards are already loaded on the drive and even more additional wizards will be available in the futu...

Page 64: ...Welcome page It explains the wizard and gives hints and tips for using the wizard Click Next 30 The Reset Parameters page is next It allows you to reset the parameters back to factory defaults Verify that both High Voltage and Normal Duty are selected from the pull down menus Make sure the radio button for Host and Ports to Defaults Preferred is selected Then click Reset Parameters ...

Page 65: ... and Ethernet Port settings Continuing to click Next until you read the Motor Control step of the wizard 31 Perform the Motor Control step of the PowerFlex 755 Startup Wizard Make the selections shown Motor Control Mode Induction Sensorless Vector Speed Units Hz Primary Speed Feedback Port 0 Param Open Loop Fdbk Position Feedback Port 0 Param Simulator Fdbk ...

Page 66: ...next This step assists in entering the data from your motor s nameplate into the drive Change the parameters to the following Power Units HP Motor NP Power 0 03 HP Motor NP FLA 0 22 Amps Motor NP Volts 230 VAC Motor NP Hertz 60 Hz Motor NP RPM 1600 RPM Motor OL Factor 1 00 Motor Poles 4 Pole ...

Page 67: ... wizard 33 The Stop Mode step is next This step assists in selecting the drive s stop mode and dynamic brake DB resistor type No selections need to be changed in this step keep the default selections Click Next to the Direction Test step of the wizard ...

Page 68: ... not needed for this example however they can be ran if you desire If you do perform the test note the following Click the button and hold it for a few seconds to run the drive As long as you hold the jog button the drive will run Once you let go of the button the drive will stop After the motors stops click the Yes radio button Observe how clicking the Yes radio button updated the screen with a T...

Page 69: ...his example however they can be ran if you desire If you do perform the AutoTune please note the test status Leaving the AutoTune page while the test is in process will abort the test faulting the drive Do not leave AutoTune page until the test is complete Note In some cases an Over Speed Fault may occur during a Rotate Tune Just acknowledge it and move on with the lab Click Next until you reach t...

Page 70: ...rse Speed 60 Hz Adjust the S Curve values and see how that changes the shape of the ramps Set it back to zero before moving on Click Next to the Speed Reference step of the wizard 37 The Speed Reference step is next It helps you select where the drive gets its speed reference Observe the screen with the default value of Port 0 Parameter 871 Port 1 Reference ...

Page 71: ...71 of 136 38 Now select the reference to be from Port 7 Parameter 50 Anlg In0 Value observe how the wizard shows the pertinent parameters for this analog input ...

Page 72: ...rt Stop step of the wizard 39 The Start Stop step of the drive is next Make the selections below DI Start Port 7 I O Module 24 V Parameter 1 Dig In Sts Bit 1 Input 1 DI Stop Port 7 I O Module 24 V Parameter 1 Dig In Sts Bit 0 Input 0 DI Forward Reverse Port 7 I O Module 24 V Parameter 1 Dig In Sts Bit 2 Input 2 ...

Page 73: ...inputs available to the user however the wizard shows the commonly programmed inputs All the available digital inputs can be accessed via the HIM or software tool See the user manual for those parameter numbers 41 Set your analog output to read the voltage from the drive by following the capture Note Port 7 I O Module 24V Parameter 50 Anlg In0 Value 42 Continue to click Next until you reach the Pe...

Page 74: ...there may be some differences between your actual screen and the one shown Click Finish The wizard will write your changes to the drive Note The Pending Changes step can be used a reference tool You can print the summary with the print button at the bottom of the window You can refer to the printed summary when commissioning duplicate drives or replacing a faulted drive 44 Use your configured inpu...

Page 75: ...xpert to allow all of the parameters to be visible 46 Click on the button in the tool bar at the top of the window 47 Read the Caution Advisory window and click OK 48 Use the buttons on the left hand side of the control bar to start stop jog and control the direction of the drive ...

Page 76: ... change Port 0 Parameter 545 Sped Ref A Sel while the drive is not running Stop the drive and change it to Port 0 Parameter 877 Port 13 Reference Start the drive again and use the slider on the right hand side to control the speed reference 49 Stop the drive and turn off the control bar by clicking the button again Observe the Caution Advisory window and click Yes ...

Page 77: ...g and Saving the Drive s Configuration to a PC 50 From the Toolbar menu select the Properties tab In the Save As window define the filename and location of the file Take note of the name and remember where you save this file it will be needed later 51 In the Properties window select Export to upload all the parameters from the PowerFlex 755 drive 52 Select the Upload Entire Device to save data fro...

Page 78: ...a Drive 57 After your file is saved and you have disconnected from the drive using what you learned previously set the drive to defaults using the HIM 58 While your CCW project is still opened go to the Toolbar menu and select the Properties tab 59 Select the Import button and select your iuux file to import parameters 60 Your steps should follow as such 61 The upload will happen fast Once done cl...

Page 79: ...Check Download check box to get detailed information on any download errors and click the Advanced button to specify which ports to download 64 If you have all peripherals on your demo box uncheck Port 6 Safe Speed Montr 65 Select Download button to download to the drive ...

Page 80: ...box similar to this one it may contain more detailed error information will appear Click Ignore to continue the Download You may have to perform this operation several times to fully complete the Download 67 Close the download status bar upon successful completion 68 Close the Connected Component Workbench software Note This concludes the guided portion of the lab ...

Page 81: ... 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 Workben...

Page 82: ...are icon on the desktop You will see the following splash screen 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 select Project File 3 Select the PowerFlex_Lab file and click the Open button ...

Page 83: ... be opened in the Logix Designer software after a few moments 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 E2P PF525_Drive The Module Properties window will appear 5 Click on the tab labeled Drive ...

Page 84: ...ards One additional feature in Logix Designer is for setting up Automatic Device Configuration ADC the drive 6 Click on the Properties button This opens the Properties window to the Setup tab which shows some basic drive information including Configuration Revision Device Language and Electronic Keying The buttons in the top right corner of the window have very useful functions as listed below Cre...

Page 85: ...g the USB port on the removable control module of the PowerFlex 525 drive lets you download the configuration to a drive that does not have main power applied This can save time and reduce the personal protective equipment requirements for programming many similar drives The PF5 and IUUX file format is compatible with Connected Components Workbench but the PowerFlex 525 is not compatible with DNO ...

Page 86: ...Drive tab The Add On Profile for the PowerFlex 755 drive in the Logix Designer software provides a common look and feel to the DriveExplorer software not covered in this class 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 the drive 12 The...

Page 87: ...s vary 14 Leave the Drive tab and proceed to the General tab Within the Module Definition section of the General tab click the Change button to open the Module Definition window 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 fro...

Page 88: ...nected Components Workbench software Just as you did earlier in the lab you can go online with the drive view and modify parameters with the Parameter AppView and CustomView groups Click on the X in the upper right hand corner to close the Parameters window 17 Back in the Module Properties screen click on the General tab The General tab is used to set the drive Name Ethernet Address and configure ...

Page 89: ...on By default drive status and control information will be communicated Status Information The DriveStatus word contains the drive status bit information such as Ready Fault and At Reference The OutputFreq word contains the speed feedback information which shows the actual operating frequency Hz of the drive Control Information The LogicCommand word contains the drive command bit information such ...

Page 90: ...ction list No parameters need to be added for this lab but take some time to scroll through the available parameters that can be assigned as Input and Output Datalinks Click on the X in the upper right hand corner to close the Module Definition window and then close the Module Properties window ...

Page 91: ...use they also allow larger systems to be designed faster 1 Create the contextual menu by right clicking on the device and select Copy 2 Select the Ethernet network and right click to show the network menu Select Paste from the list 3 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 configurati...

Page 92: ...r 5 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 th...

Page 93: ...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 7 Close the Studio 5000 Logix Designer project Click No when prompted to save changes to the project ...

Page 94: ...ck the Open icon illustrated below 2 Select the PowerFlex_Lab ACD file and click the Open button 3 Open the drive Module Properties window by double clicking on the PowerFlex 525 E2P PF525_Drive node in the I O Configuration folder The Module Properties window will appear ...

Page 95: ... button The Connection Browser window will appear 6 Expand the AB_ETH 1 Ethernet driver and select the 192 168 1 20 PowerFlex 525 node Click the OK button 7 You will be asked to confirm with the window shown below Click the button to Download Entire Device ...

Page 96: ... the drive 9 If you see this Data Out of Range message Click the Blue button and Click Ignore 10 If you see this Data Out of Range message Click the Blue button and Click Ignore You may hear the drive reset which is normal After the download is complete the Module Properties page will be back in focus on the Drive tab ...

Page 97: ... 12 Open the drive Module Properties window by double clicking on the PowerFlex 755 EENET PF755_Drive node in the I O Configuration folder 13 Click on the Drive tab 14 Click the Download button 15 From the Connect To Drive window select the 192 168 1 30 PowerFlex 755 node ...

Page 98: ...f you get this error screen Just click OK and continue That is due to the Safety Card which is not used in this lab 18 Click Download which will occur very fast 19 Click OK on the module properties window 20 Click on Communications in the menu bar and select Who Active The Who Active window will appear ...

Page 99: ...92 168 1 10 1769 L18ERM LOGIX5318ERM via the AB_ETHIP 1 Ethernet driver is selected and click the Download button The Download window will appear 22 When the confirmation window appears click the Download button again You will see a progress bar ...

Page 100: ...roller mode to Remote Run click the Yes button 25 To clear the faults after downloading the program switch the selector switch DI2 to the right hand position then back to its left hand position 26 Verify that the DI1 selector switch is in the left hand position 27 Use the green button to start both drives and red button to stop both Continue to the next section of the lab ...

Page 101: ...P SP017 The DVD provides drive selection tools CAD drawings for panel layout and wiring basic status control and diagnostic logic files FactoryTalk View ME and SE faceplates and more With these tools and the built in best practices design the system designer is free to focus on the design of their machine control and not on design overhead tasks You can also download these same supporting files fr...

Page 102: ...late Operation The Startup screen display provides machine control as well as the main navigation screen to launch all other faceplates or screens that provide additional equipment control status and alarm history This display can be configured to suit your machine or system needs Machine Control Program AUTOMATIC mode refers to the automatic function or automatic sequencing for the machine Operat...

Page 103: ...TED Press Clear Faults ABORTED CLEARING STOPPED STOPPED Press Start STOPPED RESETTING IDLE STARTNG RUNNING RUNNING Press Stop RUNNING STOPPING STOPPED The machine is placed into the ABORTED state whenever a drive fault condition and or a state transition error has been detected The machine is also placed into the ABORTED state on Power Up or during first scan i e Program to Run Mode of the control...

Page 104: ...ansition to the STOPPED state 2 Press the Program Operator button until Program is displayed Program mode AUTO is now the active control mode 3 Press the Start button The system begins operating according to the Studio 5000 Logix Designer program The description from the ladder logic program is shown here 4 Let the system run for about one minute to see the full cycle of the ladder logic Once sati...

Page 105: ... faceplate Continue to the next section Using the PowerFlex 525 Drive PowerFlex 755 Drive Faceplates The steps below also apply to both the PowerFlex 755 The faceplate screen is consistent between PF525 and the PF755 1 Press the PF525 button from the Startup screen The faceplate will appear The PowerFlex 525 faceplate provides status information fault information and trending data The faceplate al...

Page 106: ...pinning the value will be updated 3 Type a value between 0 Hz and 60 Hz and press the Enter button on the keypad to confirm The faceplate will technically allow a higher value to be entered but the drive will limit to 60 Hz in any case 4 Click the Start button in the PF525 faceplate The drive will start turning the motor at the commanded speed You can see the speed feedback changing in the numeric...

Page 107: ... determines the fault information from the drive and displays the fault type code and description When there is no active fault the display shows the last fault condition recorded 7 On the demo box push in the red Safe Off button to generate a fault on the drive This will generate a F059 Safety Open fault 8 Press the Help button for more information about the fault The Help screen displays the fau...

Page 108: ...ion from all of the devices 10 When you are finished pull out the red Safe Off button and press the Clear Faults button on the Startup screen to clear the fault in the drive and the state machine 11 Press the Configuration button From the Configuration screen you can enter display names and units as required for your application Some of the labels are used on the Equipment Status faceplate ...

Page 109: ...up 13 Press the Trend Configuration button The Trend Configuration button is only visible from the Trend screen The Trend Configuration screen lets you adjust the trend scales 14 When you have finished exploring the PowerFlex 525 drive faceplate close it by pressing the X in the top right corner of the faceplate ...

Page 110: ... each of the device modules and applies a timestamp based on the order in which it was received 1 Press the Alarm History button on the Startup screen to open the faceplate The Alarm History faceplate can be an effective diagnostic tool for troubleshooting helping machine operators pinpoint root cause for problems quickly 2 When you are done with the Alarm History faceplate close it by pressing th...

Page 111: ... the Equipment Status button on the Startup screen to open the faceplate You can configure up to nine device faceplates to run with the Equipment Status screen and each device faceplate can be launched directly from it by clicking on the device name 2 When you are done with the Equipment Status faceplate close it by pressing the X in the top right corner 3 Switch back to Studio 5000 software From ...

Page 112: ...d 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 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...

Page 113: ...guration ADC 1 From the File menu select Open to select an existing project 2 Select the PowerFlex_Lab_ADC ACD file and click the Open button Lab files are located within the C Users labuser Desktop Lab Files PF525 and PF755 Basic HIM CCW PI Lab Files folder ...

Page 114: ...operties window will appear 4 Click on the tab labeled Drive The Drive tab will appear The drive AOP requires deliberate action to enable ADC This helps ensure that ADC is fully understood prior to turning it on The drive AOP also has an ADC icon on the Drive tab that shows if ADC is enabled green arrow or disabled gray arrow for that drive 5 Click on the ADC button This will open the Automatic De...

Page 115: ...nges to take effect you must click the Apply button before closing the window with the X at the top corner 8 Click the OK button to close the Module Properties window 9 Repeat steps 3 8 for the PowerFlex 755 EENET PF755_Drive Note When enabling ADC for the PowerFlex 755 drive and its peripherals uncheck the checkbox for Port 6 20 750 S1 Safe Speed Monitoring to disable ADC for the Safety periphera...

Page 116: ...cted and click the Download button The Download window will appear 12 When the confirmation window appears click the Download button again If you reach this step in the lab but do not end up completing the entire ADC exercise please notify an instructor as you leave so that the controller may be reset for the next session ...

Page 117: ...troller back to Remove Run click the Yes button 14 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 Continue to the next section to see ADC in action ...

Page 118: ...ng the lessons from the first exercise change parameter P033 Motor OL Current to 5 0 or another value if you desire 5 Reconnect the Ethernet cable to the drive This will reinitiate communication between the drive and the controller which starts with verifying the configuration signature Notice that the PowerFlex 525 drive will get a F048 Parameters Defaulted fault on the LCD Keypad display after a...

Page 119: ... 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 driv...

Page 120: ... drive has the correct parameter now loaded for P033 Motor OL Current through the HIM or the Add On Profile using techniques you learned earlier this lab Reset the System To disable Automatic Device Configuration you can either reverse the steps of the previous section or more easily download a new program to the controller that does not have ADC enabled 1 Close the PowerFlex_Lab_ADC project file ...

Page 121: ... the machine module provides a high level interface with the HMI accepting commands like Start Stop and Clear Faults It provides status info to the HMI terminal like current state of the machine for example RUNNING versus STOPPED Application o The application modules contain all of the application specific code This is where a majority of the customizing is expected to occur and is essentially a p...

Page 122: ... of the commands may be ignored depending on the module type Each of the modules are defined as individual programs in the Logix Project Each program contains all of the necessary logic to interact with the other configured modules This interface between each of the modules is accomplished via the Monitor and Control routines located in each of the programs The machine commands and corresponding m...

Page 123: ...en down into routines that contain logic for a specific function Each module contains a monitor and control routine that provides a common interface between the machine and the application device modules Each of the routines main functions are listed below ...

Page 124: ... information from each of the application and device modules Based on the feedback information the machine will react accordingly In addition the machine module provides a high level interface with the HMI accepting commands like Start Stop and Clear Faults It provides status info to the HMI terminal like current state of the machine for example RUNNING versus STOPPED Machine States By default the...

Page 125: ... the machine module issues an ABORT command The fail safe transition timer makes sure the overall machine does not become stuck in a Transitional State It also helps to provide diagnostic information to determine which module is not transitioning properly You can fully customize the state machine letting you change the relationship between states and the state names and add or remove states if nee...

Page 126: ...126 of 136 Default Machine States Default Machine Commands ...

Page 127: ...verall machine control and status including the state machine The user defined data type consists of these components Machine Tags Device and Application Status Rungs and Logix The device and application status rungs provide feedback information to the machine module and consist of these components ...

Page 128: ...ey are used to determine the overall status of the machine They help the machine transition between states or detect a fault and respond accordingly All of the module status information is summarized in the Monitor routine of the machine module For this Drives and Motion Accelerator Toolkit DMAT application example the rungs are found in the R02_Monitor routine of the P01_Machine program ...

Page 129: ...129 of 136 DMAT Device Status Rungs ...

Page 130: ...130 of 136 DMAT Application Status Rungs ...

Page 131: ...and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic specific to your application In this example application code is shown within the R10_ApplicationCode routine of the P02_Application program In this example below is only a part of the application code is shown for the DMAT assembly application ...

Page 132: ...132 of 136 ...

Page 133: ...vice modules can also consist of multiple devices for example a drive and perhaps a feedback device for example a sensor Device Module Tags The application and individual device modules interact with each other via device specific control tags that include both command and status information The control tags consist of these data types All of the data types listed above can be modified to fit spec...

Page 134: ...rvoCtrl Tag The user defined type for the Kinetix 300 drives and the add on defined data type for the PowerFlex drives serve similar function as the UDT_ServoCtrl data type however their layouts differ Refer to the specific data types for more information ...

Page 135: ...Control Logic In this example the R03_Control routine for the P04_PF755_Drive device module initiates and or clears the Reset and Abort sequences It is the same for the R03_Control routine for the P03_PF525_Drive device module ...

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