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Application Note #1160: AGP to an Allen Bradley PowerFlex 4 Variable

Frequency AC Drive via Modbus RTU

Introduction

This Application Note is intended to assist using the GP-Pro EX Version 2.X Schneider Electric Modbus
SIO Master (or RTU) Driver with an Allen Bradley PowerFlex 4 Variable Frequency AC Drive. The
AGP3000 HMI product family, along with GP-Pro EX interface development software, supports a wide
range of communication drivers. The Modbus RTU driver takes advantage of the Modbus protocol to
connect to PLC and non-PLC devices, such as drives, inverters, and temperature controllers.

Included with this Application Note is a demonstration project for GP-Pro EX which tests Modbus
functions supported by the Allen Bradley PowerFlex 4 Drive.

Future updates to hardware or software from either manufacturer may affect some of these steps.

Materials:

1.) Proface GP-Pro EX Screen and Logic Editing software v2.X or higher
2.) Proface AGP3000 Series HMI
3.) Allen Bradley PowerFlex 4 Variable Frequency AC Drive
4.) Pro-face CA3-ADPCOM-01 Port Adapter or CA4-ADPONL-01 COM2 Port Adapter
5.) Pro-face CA3-ADPTRM-01 Termination Adapter
6.) Category 5 Shielded 8-conductor cable with a shielded male RJ45 connector.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Build the Cable:

The PowerFlex 4 Drive communicates using the Modbus RTU protocol via the RJ45 (DSI) port located
on the front.

1.) To make this cable connection quickly, use the following Pro-face cable adapters:
a.) CA3-ADPTRM-01 Breakout Adapter
b.) CA3-ADPCOM-01 Port Adapter for COM1 (*AGP3302B COM2) or CA4-ADPONL-01
port Adapter for COM2 (*Not for use with AGP3202B)

2.) In the enclosed demonstration project, COM1 on the AGP3300T is connected to the PowerFlex
4 Drive via RS422\485 2 Wire communication. For this reason, the following cable diagram
indicates to use the CA3-ADPCOM-01 adapter. If COM2 will be used in your project, simply
substitute the CA4-ADPONL-01 adapter for the CA3-ADPCOM-01 adapter. These port
adapters are not simply gender changers.

If you wish to build your own cable without using the Proface adapters select the correct diagram
below:

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Configure the Drive:

1.) Terminal 16 [RS485 (DSI) Shield] of the drive terminal block needs to be wired to safety ground
(PE) to use the RS-485 communications port.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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2.) Set up the following drive parameters as shown in the AC PowerFlex 4 Drive Manual for use
with the enclosed demo project. If you are creating your own application in GP-Pro EX, set the
following settings to match your GP-Pro EX Project:

P036 – 5 = [Start Source - RS485 (DSI) port.]

P037 – 5 = [Stop Source - RS485 (DSI) port.]
P038 – 5 = [Speed Reference - RS485 (DSI) port.]
A103 – 4 = [19.2K baud]
A104 – 1 = [Modbus Slave Node Address - 1]

GP-Pro EX Communication Set Up:

When creating a new project in GP-Pro EX, follow these steps to configure the AGP to communicate
with the PowerFlex 4 Drive. Once the communication settings are configured and the screens are
created, simply download the new project (or the enclosed demonstration project) to the AGP.

Note: The enclosed demonstration project was created for an AGP3300T. If this is not the model that
you are using, see the end of the Application Note for instructions on how to convert the project and
screen size to a different model.

1.) Select the Schneider Electric Modbus SIO Master driver, make sure you have the COM1 port
selected, and then click on the Communications Settings button.

2.) Click on the PLC name to configure the communication parameters.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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3.) The included demonstration project uses the following communication parameters:

4.) Next, click on the PLC icon to configure the Modbus parameters:

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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5.) Use the default parameters for the Modbus SIO Master driver for communication to the AC
PowerFlex 4 Drive:

GP-Pro EX Parts Addressing, Screen Set Up, and Usage:

Note: The PowerFlex 4 Drive uses Modbus 40000X (Holding Registers) Addresses to access the
various drive parameters. This includes reading from and writing to using Holding Registers. The
enclosed demo application has examples of each on individual screens.

Be aware that the Holding Register Address is 400001 + the numeric portion of the PowerFlex 4 Drive
Parameter ID. For instance, if you wish to reset a Fault on the drive, you would write 1 to drive
parameter register # A100. (The default value in this register is 0) In order to access this parameter via
Modbus, add 100 to the starting Modbus address of 400001, which would make the Modbus address
used to reset a Fault on the drive 400101. This is the address that is used in the GP-Pro EX Word
Switch to reset a drive fault.

This section provides typical examples of how to configure and address Parts (objects) included on the
demonstration project screens.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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1.) Single Register Write - (Screen B4)

Drive Control Bits:

This screen has Word Switches configured to Run, Stop, change direction, and reset a Fault on the
PowerFlex 4 Drive via Modbus For example this screen has a Word Switch configured to Run the
drive by writing a value of 2 to the Holding Register 408193. By setting this register to 2 via
Modbus the PowerFlex 4 Drive changes to “Run” mode.

In similar fashion other buttons write the appropriate value to Modbus Holding Register 408193 to
“Stop” (1), and change direction “Fwd” (16 or 10 hex) and “Rev” (32 or 20 hex.) of the PowerFlex 4
Drive. The Fault button writes a (1) to Modbus Holding Register 400101 to reset a Fault.
Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Drive Command Speed Reference:

The commanded frequency in the PowerFlex 4 Drive is parameter d002 or Modbus register
400003. (400001 + 002) . This is a read only register in the drive. Entering a new command
frequency in the drive is accomplished by writing to register 8193 in the drive or Modbus 408194.
This is a write only register in the drive. Attempting to read a write only register or to write a read
only register will result in a communication error.

A script is used to read the current commanded frequency and move it to the AGP internal memory
location LS0200 for display in a numeric data entry window. (Script is required because 400003 is
a read only register and Allow Input is enabled in the Data Display.) When a new value is entered
in the Data Display it is written to LS0200 and an Input Complete Flag is set at LS020400. Then
the screen script to writes the new value to the write only Speed Reference register 8193 using
Modbus register 408194.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Note that if a new speed reference that is out of range is entered the drive will automatically adjust it
to a valid value.

2.) Status Bits Read (Holding Register) (Screen B2)

The PowerFlex 4 Drive does not allow accessing data bits within registers directly. To display drive
status on the AGP requires reading the Drive Status word 8448 or Modbus Holding register 408449
in script and writing it to an internal variable to access the bits. (In this demo example LS202)

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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The script has the trigger set to Continuous Action. The Continuous Action trigger renews the
status information each time the displayed screen is updated. The value of register 8448 or
Modbus 408449 is copied into LS0202 to allow bit access by lamp indicators on the screens. The
indicators are linked to the appropriate bit in LS202.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Single Register Read\Write (Holding Register) (Screen B9)

This screen allows you to view the values of Holding Register 400035 (40001 + Offset of 34) and
400036 (40001 + Offset of 35). The Numeric Display part has Allow Input and Pop-up Keypad
enabled to allow the values to be changed.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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3.) Single Register Read\Write with Scrolling (Holding Register) (Screen B10)

This screen simply allows scrolling through all the possible Holding Registers in the drive starting at
40001 + an Offset. If you push the Up arrow, then an Offset of 1 is added to the current Holding
Register address. The reverse is true if you press the Down arrow, an Offset of 1 is subtracted from
the current address (which is stored in the GP-Pro EX Symbol “Single_Offset”).

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
Page 12 of 17
 United States Canada Mexico

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
Page 13 of 17
 United States Canada Mexico

This screen is also set up to allow keypad input of the address and value of the Holding Register if
the Numeric Display for each is touched on the screen.

In this example, the Holding Register 400036 can be seen by entering 35 in the Offset Numeric
Display part on the screen. This is the same Holding Register that is shown on Screen B9 (example
2) and had a value of 60. If the value is changed on this screen to 90, then by pushing the SINGLE
REG. READ navigation button at the screen changes to the Single Register Read/Write screen
where the new value can also be seen.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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Operator Control Screen B20:

The demonstration project includes a screen “Operator Panel”. It includes common operator interface
controls on a single screen for your convenience. All other screens in this project can be deleted. If the
“Main” screen is deleted a new startup screen must be selected in Display Unit. If the “Operator Panel”
is copied to another project, also copy the global script from this project. The global script is needed for
the status indicators to function.

How to convert enclosed demonstration project to a different model\screen size:

In order to use the enclosed demonstration project, which was configured for an AGP3300T, to a
different model and screen size, follow these steps.

1.) Open the enclosed GP-Pro EX project, click on the Project menu then System Settings.

2.) Click on Display in the System Settings menu then Change Display Unit.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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3.) Select the series line and model of the new AGP. Make sure to click the Convert Resolution
check box in order to automatically resize all screen objects in the application.

4.) Click OK to the reminder to check the screen objects before downloading to an AGP.

5.) Click YES to acknowledge that AGP models have hardware capabilities.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
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6.) Inspect the demonstration project screens and objects to verify that they were converted and scaled
properly.

For more information on Pro-face and our full line of HMI, Operator Interface and Industrial PC products
please visit out web site at www.profaceamerica.com.

Title: AGP to an Allen Bradley PowerFlex 4 Variable Frequency AC Drive via Modbus RTU • AN#: 1160 • Date: July 2008 •
Revision: C

Pro-face, 750 North Maple Road, Saline, MI 48176, Phone 734-429-4971, Fax 734-429-1010, www.profaceamerica.com
Page 17 of 17