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Drive Programming with the PowerFlex® 525 AC

Drives

For Classroom Use Only!

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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.

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Drive Programming with the PowerFlex® 525 AC
Drives

Contents
Before you begin ........................................................................................................................................... 5
About this lab .................................................................................................................................................................................... 5
Tools & Prerequisites ........................................................................................................................................................................ 5
Network Setup ............................................................................................................................................... 6
About the Demo Box ..................................................................................................................................... 7
Exercise 1: Using the HIM Keypad and Display ........................................................................................... 8
Information ........................................................................................................................................................................................ 8
Reset Drive to Defaults ................................................................................................................................................................... 12
Configuring Drive Parameters......................................................................................................................................................... 14
Exercise 2: Utilizing Ethernet/IP and Connected Component Workbench™ ............................................. 15
Connecting to the Drive .................................................................................................................................................................. 15
Exploring Drive Parameters via Parameter Groupings, AppView™, and CustomView™ .............................................................. 18
PowerFlex 525 Start-Up Wizard ..................................................................................................................................................... 24
Exercise 3: PowerFlex 525 Drive Add-On Profile with Drives and Motion Accelerator Toolkit. ................. 33
About Integrated Drive Profiles and Premier Integration ................................................................................................................ 33
Using RSLogix 5000 with the PowerFlex 525 Drive Add-On Profile ............................................................................................... 34
About Drives and Motion Accelerator Toolkit (DMAT) .................................................................................................................... 46
Switch to the HMI Application ......................................................................................................................................................... 46
Faceplate Operation ....................................................................................................................................................................... 47
Appendix A: Overview of the DMAT ........................................................................................................... 55
Machine/Application/Device Module Relationship .......................................................................................................................... 56
Module Routine Overview ............................................................................................................................................................... 57
Machine Module.............................................................................................................................................................................. 58
Machine States ............................................................................................................................................................................... 58
Machine State Diagram .................................................................................................................................................................. 59
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.......................... 61 Application Modules ......................................................... 65 Device Module Control Logic .............................................................................................................................. 69 Notes: ......................................................................................................................................................................................................................................................................................................................................................................................... 60 Default Machine Commands....................................... 60 Machine Control Module Tags ........Default Machine States ........................................................................................... 61 Device and Application Status Rungs and Logix .................................................................................................................................................. 61 Machine Tags ...................................................................................................................................................................................................................................................... 70 4 of 70 ....................................................................................................................................

About this lab Learn the basics of drive programming using the new PowerFlex 525 compact AC drive.11/26/2012 (beta) • Connected Components Workbench™ v2.131. You will also try out AppView™.46 (beta) Ethernet patch cables Files required • PF525_Lab.02. Attendees will configure these drives using the Human Interface Module (HIM).59.07 • IDFCCWInstaller v3.01.02 • FactoryTalk View Studio v6.013 o PowerFlex 525 v1.13 (beta) Hardware devices required • PowerFlex 525 Demo Box (12P019A) • o 1769-L18ERM-BB1B v20.mer *NOTE* Lab files are located within C:\Lab Files\Drive Programming with the New PowerFlex® 525 AC Drives 5 of 70 .002.06.00 • PowerFlex525 AOP for RSLogix5000 v17+ v1.04 • Wizards v3.0 .Before you begin Please review the following information before starting this lab.09 • RSLinx Enterprise v5.ACD • PF525_Lab.01. Connected Components Workbench™ and RSLogix 5000.00.00.10. Tools & Prerequisites Software programs required • RSLogix 5000™ v20. a new feature that provides specific parameter groups for popular applications.11/26/2012 (beta) • RSLinx Classic™ v2.50.00.557 . experience the drive’s ease of integration into the Logix environment using the embedded Ethernet port and add-on profiles in RSLogix 5000™. Finally.00.

Network Setup Ethernet Connections 1 2 3 6 of 70 PC L18ERM Port 1 (front) L18ERM Port 2 (rear) ETAP Port 1 (front) ETAP Port 2 (rear) PF525 .

About the Demo Box 7 of 70 .

Exercise 1: Using the HIM Keypad and Display In this section you will perform the following: • Review key information about the HIM keypad and display of the PowerFlex 525 • Reset the PowerFlex 525 drive to defaults • Configure several parameters Information The PowerFlex 525 is easy to configure with flexibility in programming options to meet your application. One of which 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 o Three adjustable speeds • Full Alphanumeric with 5 Digits and 16 Segments • Supports multiple languages o English o French o Spanish o Italian o German o Portuguese o Polish o Turkish o Czech 8 of 70 .

Display and Control Keys • • AppView: Dedicated sets of parameters grouped together for the following applications o Conveyor o Mixer o Compressor o Centrifugal Pump o Blower o Extruder o Positioning o Textile / Fiber CustomView: Parameter Groups can be customized specifically for your application o Add up to a max of 100 parameters o Save new “CustomView” for easy copy and paste 9 of 70 .

Control and Navigation Keys 10 of 70 .

Just read through the following. 11 of 70 .Viewing and 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.

If the RUN LED on the controller is lit. 12 of 70 . Make sure the L18ERM controller is NOT in Run Mode. Pres the Stop button to clear the fault from the drive. Press the Esc button until you see on the keypad display. Make sure DI1 is in the Left position 2. move the switch to PROG (bottom/down) position then REM position (middle). 3.Reset Drive to Defaults 1.

Pres the Stop button to clear the fault from the drive. Press the Enter or Sel button parameter in that group will flash. The drive will fault with a scrolling message of “F048 – Parameters Press the Enter Defaulted” See picture below. 6. you can also press Sel or bit that you can change will flash. Once is displayed. If you wait one (1) second. Press the Select button and use the Up or Down arrows Basic Program group or until you see the on the HIM display. 8. you will Use the Up notice that the HIM display scrolls with P053 – Reset to Defaults. The right digit of the last viewed and Down Rather than pressing the Up parameters in numerical order. or Down arrows until you see P053. Note: to enter the Basic Program group. 9. Press the Up or Down arrows to scroll through many button to move from digit to digit or bit to bit. You will see “0 . button to confirm.4. 5.Ready/Idle” scroll arrows until you see “2 – Factory Reset”. 13 of 70 . 7. The digit button. Press the Enter across the display.

“SVC” (Sensorless Vector) Note: Refer back to the Viewing and Editing Parameters section as needed. you are able to quickly configure and control the drive with its HIM keypad. Take what you have learned about the keypad operation from the Reset Drive to Defaults section to make the following Basic Program group parameter changes: • P033 – Motor OL Current = 0. Make the following Communication group parameter changes: • button to stop the drive. subnet mask and gateway address with a BootP or DHCP server. Press the Start button and use the drive pot to change the speed reference as well as the Reverse reverse directions. Press the Stop 4.“Disabled” This parameter enables BootP or DHCP to set the IP address. • 2. Identifies the connections that would be attempted on a reset or power cycle.2 Amps • P036 – Motor NP RPM = 1600 RPM P037 – Motor NP Power = 0.2 Amps • P034 – Motor NP FLA = 0. 14 of 70 . button to change from the forward and 3. cycle power to the drive by using the Drive Power selector switch located in the bottom left corner of the demo box. With the drive’s default “out-of-the-box” settings and including the above parameter changes.03 kW • P039 – Torque Perf Mode = 1 . • C129 – EN IP Addr Cfg 1 = 192 • C130 – EN IP Addr Cfg 2 = 168 • C131 – EN IP Addr Cfg 3 = 1 • C132 – EN IP Addr Cfg 4 = 20 • C133 – EN Subnet Cfg 1 = 255 • C134 – EN Subnet Cfg 2 = 255 C135 – EN Subnet Cfg 3 = 255 • 5. Set C128 to “Disabled” when using the drive parameters to set its Ethernet/IP communication configuration. In order for communication settings to take effect. C128 – EN Addr Sel = 0 .Configuring Drive Parameters 1.

as well as the PowerFlex® 4-class drives and PanelView™ Component graphic terminals. version 3. For this lab.Exercise 2: Utilizing Ethernet/IP and Connected Component Workbench™ Currently. you will be using a released version of the Connected Components Workbench™ software with a beta engineering add-on installer to allow Connected Components Workbench™ software to support the PowerFlex 525 drive. will support the PowerFlex 525 drive.  Create a CustomView™  Explore the Startup wizard. Go to the computer’s desktop and double click the Connected Components Workbench™ You will see the following splash screen while the software loads. A future release of Connected Components Workbench™. Connecting to the Drive 1. for your small machine applications. In this section you will perform the following: • Connect to the PowerFlex 525 through the embedded Ethernet/IP via Connected Components Workbench™  Explore the different parameter groupings as well as the AppView™. 15 of 70 shortcut. . Connected Components Workbench™ programming and configuration software supports the Micro800™ controllers.

Note: You may want to maximize the Connected Components Workbench™ software to make viewing easier. There are many features to Connected Components Workbench™. 4. Click the [+] next to the Discover within the Device Toolbox. Click the Browse Connections button to launch the RSWho connection browser. 16 of 70 . Mainly. we will be using the software to go online with the PowerFlex 525. The main screen for Connected Components Workbench™ is as follows. 3.2.

Click/Highlight the 192.1.20.168. Ethernet. you might see a connection status window. Press the OK button to initiate the connection process. Click on the [+] to expand AB_ETH-1. 17 of 70 . For a quick moment. you will see the following main screen with a green highlighted “Connected” for the PowerFlex 525 within the Connected Components Workbench™ software. 6.50HP device. once the connection process is complete. PowerFlex 525 1P 110V . Otherwise.5. The lab’s preconfigured RSLinx driver.

Exploring Drive Parameters via Parameter Groupings, AppView™, and CustomView™
1.

There are many features supported by Connected Components Workbench™ for the PowerFlex 525 as shown below.

Take some time to explore them.
2.

Click on the Parameters

icon to view the PowerFlex 525 drive parameters as seen below.

The PowerFlex 525 Drive Add-On Profile has a nice new feature from Connected Components Workbench™ software
that will show the non-default parameters. This makes it easy for users to find out in a simple view what parameters
were changed from their default setting. This button only updates the set of parameters shown based on the upload. If
parameter “x” changes from defaults after clicking the button, it won't be added to the display until the view is
refreshed.
3.

Make sure All Parameters is selected within the Group dropdown selection box and then click the Show NonDefaults button as shown below.

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4.

A upload progress window will pop up.

5.

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 Lab 1 appear in this list. Example shown
below.

6.

Click the Show All

7.

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.

button to return to viewing all of the PowerFlex 525 drive parameters.

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Try some other examples such as Dig , Speed, 10 and see the results. Remember to clear/delete the entry when
finished.
8.

Under the Group: dropdown selection box, you can scroll through the different drive parameter groups, AppView™ and
the CustomView™.

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For example. Scroll through these application specific parameters. Communications and Advanced Program for more startup/commission parameters. No more guessing what parameters you need to change. some are shown below. Take some time to explore some of the other parameter groupings such as Terminals. within the Group dropdown selection box. 21 of 70 . drive parameters for that application are all in one convenient location. Click on Basic Program and explore the parameters shown below. 10. click on the Conveyor AppView™. These are the most simplistic parameters that are needed to start up/commission a PowerFlex 525 drive.9. The PowerFlex 525 drive has several AppView™ groupings that are tailored for a specific application to make the respective drive startup/commission simpler.

type in ABC’s Group in the Group Name box highlighted by #4. The PowerFlex 525 drive has a CustomView™ which is an application set that can be customized specifically for your application. 12. This makes adding parameters go a lot faster. Note: You can also select/highlight multiple parameters then click the Add .> button. You can add up to a max of 100 additional parameters and save the new “CustomView”. 22 of 70 . Here you will be able to select and add parameters into a nameable custom group. In this example. Select CustomView from the Parameter Group dropdown selection box and click on the Edit Group button.11. The Edit Custom Group window will appear.

Minimum Freq Parameter 44 .Torque Perf Mode Parameter 40 . Click [X] in the upper right hand corner to Close the Parameters – PowerFlex 525_1* window. 23 of 70 . 14.Autotune Parameter 41 . Add the following parameters: Parameter 30 .Maximum Freq Parameter 45 .Motor NP RPM Parameter 37 .Start Source 1 Parameter 47 .Relay Out1 Sel Parameter 81 .Motor OL Current Parameter 34 .Motor NP Poles Parameter 36 .Motor NP Volts Parameter 32 .Motor NP Power Parameter 39 .DigIn TermBlk 03 Parameter 64 .Motor NP FLA Parameter 35 .13.Motor NP Hertz Parameter 33 .DigIn TermBlk 02 Parameter 63 .Accel Time 1 Parameter 42 .Decel Time 1 Parameter 43 .DigIn TermBlk 05 Parameter 76 .2-Wire Mode Parameter 65 .Language Parameter 31 .Relay Out2 Sel Once the parameters have been added Click OK.Speed Reference1 Parameter 62 . Notice how the parameters entries from above are all now in the ABC’s Group CustomView™ for easy parameter viewing and editing.Stop Mode Parameter 46 .

Click the Next > with exploring the startup wizard. Below is the Welcome screen for the PowerFlex 525 Startup Wizard. • Reset all settings to factory defaults but retain the custom parameter group. 2.PowerFlex 525 Start-Up Wizard 1. Here you have a couple different options. Below is the Reset Parameters page. • Reset all settings to factory defaults (including the custom parameter group). • Reset only the “Power Parameters”. 3. Click on the Wizards button and Select the PowerFlex 525 Startup Wizard and Click the Select button to launch the PowerFlex 525 Startup wizard. 24 of 70 button to proceed .

page. . 4. “Reset all settings to factory defaults but retain the custom parameter group” Click Yes and once you see.Click the Reset button for the first option. 25 of 70 button to proceed to the next . Click the Next > Make sure English is selected in the Language dropdown selection box. Click the Next > button to proceed to the next page.

Remember to Click the Next > button to proceed to the next page 26 of 70 . verify and if needed. modify the parameters according to the following screenshots. Go through.5.

27 of 70 . if desired. by Clicking Next.NOTE: You may skip the Direction Test. NOTE: You may skip the AutoTune. by Clicking Next. Press Stop to Clear Fault if drive is faulted. if desired.

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You will see the following screen. Go to the Pending Changes page for a summary of the planned programming changes you have made to the PowerFlex 525 drive. to the left of the page name / icon. button for the ethernet communication Click OK. You will hear the PowerFlex 525 cycle power and the HIM Keypad display turn off and on and start scrolling the drive power ratings 8. This is a pretty quick process. Click the Reset settings to take affect. Make sure all the Pages have the black check Click the Finish >> 7. The main PowerFlex 525 window will be present. Click OK.6. Once changes have been made. button to accept pending changes. 30 of 70 .

You will screen the main PowerFlex 525 screen go from this… to this once…the Connected Components Workbench™ software has re-established it’s connection with the drive. 31 of 70 .9. Click No. When prompted. Click No. Exit Connected Components Workbench™ software by When prompted. 10.

Press the RED PF525 Drive Stop pushbutton to stop the drive. Use the Drive Pot change direction. With some simple configuration changes within Connected Components Workbench™ software. Toggle the PF525 Drive Start selector switch to start the drive. we can now use the demobox I/O to control the PowerFlex 525 drive. 32 of 70 . 12.11. to change the speed reference as well as the PF525 Drive DIR selector swtich to 14. Make sure the PF525 Drive DI1 selector switch is in the RIGHT position. 13.

Integrated Drive Profiles are "Add-On" Profiles. • Saving all drive configurations in the RSLogix project file and in the Logix controller – providing a single source of drive configuration data. alarm and event information is integral to RSLogix 5000.eliminating I/O mismatch errors.eliminating the need to convert from one data type to another. This section will provide an early preview of the PowerFlex 525 Drive Add-On Profile RSLogix 5000 as well as the PowerFlex 525 Drives and Motion Accelerator Toolkit Add-On Instructions and Faceplates for the PowerFlex 525. • Allowing the dynamic selection of drive parameters transmitted as network I/O – communicating only what is needed for the application. fault.Exercise 3: PowerFlex 525 Drive Add-On Profile with Drives and Motion Accelerator Toolkit. • Drives can be flash updated from RSLogix 5000. • Configuring both controller and drive network connections from a single location . • Auto-generating respective tag data types . Integrated Drive Profiles in RSLogix 5000 can reduce drive system development time by as much as 70% (figure obtained from timed side-by-side drive configuration comparison testing) by: • Providing one software tool to configure the entire Logix / drive system. various software components. DriveTools SP.eliminating the need to enter individual tag descriptions. About Integrated Drive Profiles and Premier Integration Integrated Drive Profiles were designed to save system development time and to make systems easier to maintain. and PC operating system. Systems using the Integrated Drive Profiles in RSLogix 5000 are also easier to maintain: • Drive diagnostic. Having a single repository of drive configuration data (in RSLogix project file) speeds drive replacement. • Allowing use of the same easy-to-use drive configuration Wizards used in Connected Components Workbench™. 33 of 70 . • Providing Copy & Paste capability when creating additional duplicate drives – also duplicates the drive configuration settings so all the new drive needs is a different node address. • Auto-generating descriptive tag names . • Drive Tech Support Wizard can be run from RSLogix 5000 to collect all pertinent information about a drive. and DriveExplorer. meaning new profiles can be introduced at any time (not tied to a specific RSLogix 5000 release) and are utilized by RSLogix 5000. its peripherals.

Click the Open folder… Select the PF525_Lab. or from the Start menu. You will see the following splash screen. *NOTE* Lab files are located within C:\Lab Files\Drive Programming with the New PowerFlex® 525 AC Drives 34 of 70 . icon on the desktop. 2.Using RSLogix 5000 with the PowerFlex 525 Drive Add-On Profile 1. select Double-click the RSLogix 5000 All Programs > Rockwell Software > RSLogix 5000 Enterprise Series > RSLogix 5000.ACD file and Click Open. Start the program. A pre-configured RSLogix 5000 program has already been created for your convenience.

the Drive tab utilizes Connected Components Workbench™. view and compare drive parameters as well as access the drive’s wizards. 35 of 70 . the PowerFlex 525 has a new look and feel. download. However.3. For the PowerFlex 525 Add-On Profile. View the PowerFlex 525-EENET Drive tab. the basic functionality is still the same when it comes to having the ability to upload. Click on the Drive tab. 4. so when compared to previous Drive Add-On profiles. You can also setup Automatic Device Configuration (ADC) your PF525 drive. Open the PowerFlex 525-EENET module properties by Double-click on the PowerFlex 525-EENET node in the I/O Configuration folder to display the Module Properties screen.

5. Click on the Communications tab to view the settings you can manually configure the PowerFlex 525 drive ethernet network settings or obtain via BOOTP or DHCP.csf files from DriveExecutive / DriveExplorer. revision. device language and electronic keying. There is also import / Export for the PF525 USB connection file format. It can be used for saving/restoring configurations. which shows some basic drive information. = Creates device database from online drive to add new revisions and configurations = Reset device data to factory defaults = Print 6. 36 of 70 .pf5. Click on the Properties button.dno / *. IT DOES NOT import *. This opens the properties window and the Setup tab. . 7. such as configuration.

37 of 70 . Going back to the PowerFlex 525-EENET Module Properties screen. Click on the [X] in the upper right hand corner to close the Properties window. Click on the [X] in the upper right hand corner to close the Parameters window 11. The General tab is used to set the following drive’s name. 9. view and modify parameters with the Parameter. ethernet address and module definition.8. This is the same as what you performed in the previous section with using the Connected Components Workbench™ software to go online with the drive. The Parameters icon launches the Parameters window. AppView™ and CustomView™ groups 10. Click on the General tab.

you can perform the following actions: • Select the drive rating • Set the firmware revision • Set the Electronic Keying • Configure the Input and Output Datalinks • Create Database from the online drive or download from the web. 38 of 70 .12. Within the Module Definition window. Click the Change… button to open the Module Definiton window.

The PowerFlex 525 allows datalinks to be configured to drive parameters. click the button to open the respective parameter selection list. Forward. drive status and control information will be communicated. Control Information The “LogicCommand” word contains command bit information. our drive I/O assembly is dynamic and gives the programmer the ability to pick & choose the desired parameters to communicate as network I/O. Instead of offering fixed I/O assemblies where what-you-see-is-what-you-get. such as Stop. and Clear Faults. The “Feedback” word contains the speed feedback information. The “Reference” word contains the commanded reference value for the drive to run. By default. Status Information The “LogicStatus” word contains the Logic Status bit information. Start. which shows the actual operating frequency (Hz) of the drive. Reverse. and At Reference. Fault. such as Ready. Click on the [X] in the upper right hand corner to close the Module Definition window 39 of 70 . Datalinks Datalinks are pointers to drive and/or other port parameters. 13.The PowerFlex 525 Add-On Profile provides the ability to configure Up to 4 words of Input Data and 4 words of Output Data can be defined for the embedded Ethernet connection. Take some time to scroll through the available Input and Output Datalink parameter selections. To configure the Input and Output datalinks.

including the drive parameter settings. All the user has to do is change the IP address. open the drive’s AOP and download the configuration! 15. and give the drive a new name.ACD is downloaded to the controller.ACD file)! It also resides in the ControlLogix when the .14. Integrated Drive Profiles are not only easy-to-use. This provides a convenient local resource for a node’s configuration settings should the node need replacing. Double-click on the Controller Tags under the Controller folder and expand the PF525_Drive:I inputs. View the input tags. If your application required multiple duplicate drives. Just connect to the controller. All node information is copied. Where do you think the drive configuration data gets stored? The drive configuration data for each node is actually stored in your RSLogix 5000 project (the . they also allow larger systems to be designed faster. It may be necessary to drag the “Name” column right margin in the header to view the full input tag names. 40 of 70 . you could right-click on the PowerFlex 525-EENET to copy it and then right-click on the Ethernet network and paste it as many times as needed.

View the output tags. Now expand the PF525_Drive:O output to view the output tag names. Note that the proper data types are used for every tag. DC Bus Voltage and Drive Temp. 16. Close the Controller Tags window by clicking the lower [X] button in the upper-right corner of the screen. Note that the proper data types are used for every tag. 41 of 70 .Descriptive tag names have been created for the configured I/O. The Drive Status bits (BOOLs) are clearly defined as well as the Feedback and Input Datalinks Output Current. The Logic Command bits (BOOLs) are clearly defined as well as the Reference. Descriptive tag names have been created for the configured I/O.

Open the PowerFlex 525-EENET module properties by Double-click on the PowerFlex 525-EENET node in the I/O Configuration folder to display the Module Properties screen. Re-open the PF525_Lab project. Click on File and Close the RSLogix 5000 program Click No to not save changes 18. 20. Select the PF525_Lab.17. Click the Open folder… 19.ACD file and Click Open. 42 of 70 .

1. Ethernet drive and Select the 192. Click on the Drive tab. Click the Download PowerFlex 525 drive. Download the entire device 24. 25. 22. button and Expand the AB_ETH-1. 43 of 70 .20. 23. Click OK.21. Click Apply and OK to close the Module Properties window. For a brief moment.168. you will see a downloading progress bar while the parameter settings are being sent to the drive.

168.26.10 via the AB_ETH-1 ethernet driver is selected and click Download. 27. Download the PF525_Lab project to the controller by clicking on Communications then Who Active. If prompted to confirm Remote Run. click Yes. 44 of 70 . Click Download again 28. Either click on the mode drop-down arrow and select Run Mode or switch the controller key to the Run position. Put the controller in Run mode. Make sure the path to the CompactLogix controller at 192.1.

45 of 70 .29. Make sure DI1 is in the LEFT position Continue to the next page.

About Drives and Motion Accelerator Toolkit (DMAT) Publication IASIMP-QS019 is a quick start guide which provides step by step instructions for using the Drives and Motion Accelerator Toolkit (DMAT) to help you design. depending on the status of the machine. the system designer is free to focus on the design of their machine control and not on design overhead tasks. FactoryTalk View ME and SE faceplates. operate. plus it allows navigation to all other screens. basic status. install. the FactoryTalk View project has already been made. It may look a little different.com/go/iatools on the Beyond Getting Started tab. and maintain a drive system. publication IASIMP-SP017. In this section. All the supporting files are included on the Drives and Motion Accelerator Toolkit (DMAT) DVD. http://www. 2. If the warning screen is displayed. 46 of 70 . Take a moment to familiarize yourself with the Startup screen before moving on to the next section. layout and wiring drawings. Switch to the HMI Application 1. and diagnostic logic files.ab. With these tools and the built-in best-practices design. You will explore the runtime application. Minimize RSLogix 5000 so that the HMI screen on the desktop can be seen. click OK to load the Startup screen. You can also download these same supporting files from the Rockwell Automation Integrated Architecture Tools website. CAD drawings for panel layout and wiring. The Startup screen should now be displayed… The Startup screen provides Machine Status and Control. and pre-configured logic and HMI files to assist you in creating an Integrated Architecture solution for your application requirements. Included are selection tools. and more. 3. The DVD provides drive selection tools. control.

the Machine operates based on the following state diagram… The states with a dashed outline indicate a transitional state. status. like start. and alarm history. etc. The Program/Operator selector button lets you toggle between the two modes. Machine Control Program (AUTOMATIC) mode refers to the automatic function or automatic sequencing for the machine. When you are done with the Equipment Status faceplate.4.e. The Clear Faults button attempts to clear faults on all devices. reverse. Faceplate 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. Click on the State Diagram button. Program to Run Mode) of the controller. This display can be configured to suit your machine or system needs. jog. The condition that caused the fault must be corrected before the clear is successful. Depending on your current machine state. The machine is also placed into the ABORTED state on Power Up or during “first scan” (i. While in Program mode. forward. Refer to the Alarm History faceplate to determine the cause for the ABORTED condition. The machine status indicators provide a summation view of all the devices for the entire machine. Operator (MANUAL) mode allows for some manual operations. close it by pressing the [X] in the top-right corner. 47 of 70 . use the following commands to transition between states: ABORTED – Press Clear Faults ABORTED  CLEARING  STOPPED STOPPED – Press Start STOPPED  RESETTING  IDLE  STARTNG  RUNNING RUNNING – Press Stop RUNNING  STOPPING  STOPPED Note: The machine is placed into the ABORTED state whenever a drive fault condition and/or a state transition error has been detected. stop. while the solid line indicates an end state.

Press Program/Operator button until Program is displayed. 48 of 70 .Run the Machine Follow these steps to start and stop the system in Program mode. 5. 3. Program (AUTO) is now the active control mode. Press Start The system begins operating according to the RSLogix 5000 program. Continue to the next page. Press Stop The system stops. Press Program/Operator. Let the system run for about one minute. When in Operator (MANUAL) mode. 4. The machine must be stopped before you can switch control modes. . If the machine is currently in the ABORTED state… …press Clear Faults. you can individually control each axis from its corresponding faceplate. After a few moments the machine should transition to the STOPPED state. 1. 2. .

PowerFlex 525 Faceplate 6. Click the Start Button from the PF525 faceplate. and trending data. fault information. 9. 8. Type in a value 0 to 60 Hz and press the Enter on the keyboard to confirm. Click on the outlined numeric entry to display keypad to change the speed reference of the drive. Click the Stop button from the PF525 faceplate 49 of 70 . 7. Press the button from the Startup screen to launch the faceplate… The PowerFlex 525 faceplate provides status information. The faceplate also includes the ability to manually control the drive.

If a fault condition exists. This will generate a F059 – Safety Open fault. If there is no active fault. Press the button. To easily generate a fault. the icon flashes RED. Push In the RED Safe Off button. 50 of 70 . On the PowerFlex 525 demo box. The Fault display determines the fault information from the drive and displays the fault type. code and description. the display shows the last fault condition recorded.10.

. The Help screen displays the fault descriptions and actions. Pull Out the RED Safe Off button and Clear the fault. You can clear faults from the Startup screen or. When you are finished. 51 of 70 .. from the Fault display. The Alarm History screen logs fault information from all of the devices. to clear both the drive fault and machine status fault.11. Press the button… From the Configuration screen you can enter display names and units as required for your application. Press the button. Some of the labels are used on the Equipment Status faceplate. if in Operator mode. Press the 12. Press the arrows to switch between screens.

13. 14. Press the button... The Trend Configuration button is only visible on the Trend screen. The Trend Configuration screen lets you adjust the trend scales. 52 of 70 . Press the button… The Trend screen lets you view Speed Feedback and any other pens are setup up.

The Alarm History Faceplate The Alarm History faceplate provides a summary of current and past alarms for all of the configured devices or drives configured in the application. When you are done with the Alarm History faceplate. The faceplate receives fault information directly from each of the device modules and applies a timestamp based on the order in which it was received. 53 of 70 . close it by pressing the Close button on the bottom of the screen. helping machine operators pinpoint root causes quickly. The Alarm History faceplate can be an effective diagnostic tool for troubleshooting.

When you are done with the Equipment Status 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. review Appendix A: Overview of the DMAT. 54 of 70 . The Equipment Status faceplate works in conjunction with individual device faceplates and provides a single summary display of all the devices that may be configured for an application. You have completed the Drive Programming with the PowerFlex® 525 AC Drives Lab. If time permits. close it by pressing the [X] in the top-right corner.The Equipment Status Faceplate The Equipment Status faceplate lets you quickly load and configure a summary display of preconfigured status and diagnostic displays (faceplates).

Device modules can also consist of multiple devices (for example. Stop. This is where a majority of the customizing is expected to occur and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic specific to your application. It provides status info to the HMI terminal like current state of the machine (for example. Modularity lets you decide which components to incorporate into your machine. The machine module was built around a simple state machine that you can customize to fit most applications. the machine module provides a high level interface with the HMI. Based on the feedback information. providing greater flexibility and a custom fit. the machine will react accordingly. was developed around a modular concept. a drive) and perhaps a feedback device (for example. o Typically. Application o • The application modules contain all of the application specific code.Appendix A: Overview of the DMAT The Drives and Motion Accelerator Toolkit DVD. publication IASIMP-SP017. 55 of 70 . and Clear Faults. the device module consists of a physical drive. The machine module broadcasts out commands and receives feedback information from each of the application and device modules. This logic reduces the programming effort required by most applications providing more time for the proprietary logic needed for the application. a sensor). Device o Device modules contain all of the logic to control the essential functions required by the device. but could also consist of a virtual or feedback-only axis. o In addition. RUNNING versus STOPPED). Logic Module Overview • • Machine o The machine module contains the high level control for the entire machine. The preconfigured logic is specifically designed around this modular concept and consists of three main logic module types. accepting commands like Start.

The machine commands and corresponding module status is routed through the Monitor and Control routines. 56 of 70 . This lets the modules operate independently in a modular structure. broadcasts out commands to both the application and device modules. Some 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. The individual modules perform a predefined task based on the command.Machine/Application/Device Module Relationship The machine module monitors the current state of the overall machine and based on the state and/or requests from the HMI terminal. This interface between each of the modules is accomplished via the Monitor and Control routines located in each of the programs.

Each of the routines main functions are listed below: 57 of 70 . Each module contains a monitor and control routine that provides a common interface between the machine and the application / device modules.Module Routine Overview Each module is broken down into routines that contain logic for a specific function.

Machine States By default. The machine module was built around a simple state machine that you can customize to fit most applications. RUNNING versus STOPPED). the machine program module operate based on the below overall state diagram. It provides status info to the HMI terminal like current state of the machine (for example. The machine module broadcasts out commands and receives feedback information from each of the application and device modules. the machine module provides a high level interface with the HMI. 58 of 70 .Machine Module The machine module contains the high level control for the entire machine. In addition. and Clear Faults. Stop. Based on the feedback information. accepting commands like Start. the machine will react accordingly.

Refer to the Drives and Motion Accelerator Toolkit (DMAT) Quick Start publication (iasimp-qs019_-enp. the machine module issues an ABORT command. 59 of 70 .pdf) Appendix B. If the machine module detects an error during a Transitional State or if the application or device modules fail to transition within an allotted time (10 seconds by default). the machine only remains on a Transitional State for brief period of time. It also helps to provide diagnostic information to determine which module is not transitioning properly. for information on how to customize the state machine. The fail safe transition timer makes sure the overall machine does not become stuck in a Transitional State. letting you change the relationship between states and the state names. and add or remove states if needed. Typically. You can fully customize the state machine.Machine State Diagram The machine module uses the Transitional States to move between Permanent States.

Default Machine States Default Machine Commands 60 of 70 .

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.Machine Control Module Tags The machine control data type. including the state machine. comprises the overall machine control and status. UDT_MachCtrl. The user-defined data type consists of these components. 61 of 70 .

All of the module status information is summarized in the Monitor routine of the machine module. They help the machine transition between states or detect a fault and respond accordingly. For this Drives and Motion Accelerator Toolkit (DMAT) application example.Device Module Status Application Module Status The status bits are set in the Monitor routine of the corresponding modules. These status bits are vital to the machine module. 62 of 70 . the rungs are found in the R02_Monitor routine of the P01_Machine program. as they are used to determine the overall status of the machine.

DMAT Device Status Rungs 63 of 70 .

DMAT Application Status Rungs 64 of 70 .

is only a part of the application code is shown for the DMAT assembly application. 65 of 70 . application code is shown within the R10_ApplicationCode routine of the P02_Application program. In this example below.Application Modules The application modules contain all of the application specific code. In this example. This is where a majority of the customizing is expected to occur and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic specific to your application.

66 of 70 .

speed reference. 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. we are using the PowerFlex 753 / 755 HMI faceplate and AOI instruction which has preprogrammed start. The control tags consist of these data types. Device modules can also consist of multiple devices. This logic reduces the programming effort required by most applications providing more time for the proprietary logic needed for the application. For this DMAT example. but could also consist of a virtual or feedback-only axis. for example.Device Modules Device modules contain all of the logic to control the essential functions required by the device. the UDT_ServoCtrl data type that is used by the integrated motion drives (CIP Motion and Sercos interface based drives) consists of these tags. Accel and Decel times. modifications to the data types could have an impact on the device module and/or other preprogrammed logic. a drive and perhaps a feedback device. stop. However. Typically. the device module consists of a physical drive. 67 of 70 . especially during import of additional device modules. a sensor. All of the data types listed above can be modified to fit specific needs of your application. for example. For example.

Refer to the specific data types for more information. 68 of 70 . however their layouts differ.CIP Motion UDT_ServoCtrl Tag Listing UDT_ServoCtrl 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.

69 of 70 . the R03_Control routine for the P03_PF753_Drive device module initiates and/or clears the Reset and Abort sequences.Device Module Control Logic In this example. It is the same for the R03_Control routine for the P04_PF755_Drive device module.

Notes: Publication CE-DM244_-EN-P — December 2012 70 of 70 Copyright© 2012 Rockwell Automation. Inc. All rights reserved. .