Rockwell Automation PowerFlex 755, PowerFlex 525 Configuration

PowerFlex® Drives Configur at ion & Programming

PowerFlex 525 & PowerFlex 755 AC Drives

For Classroom Use Only!

Important User Informati on

This documentation, whether, illustrative, printed, “online” or electronic (hereinafter “Documentation”) is intended for use only as
a learning aid when using Rockwell Automation approved demonstration hardware, software and firmware. The Documentation
should only be used as a learning tool by qualified professionals.

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Reproduction of the contents of the Documentation, in whole or in part, without written permission of Rockwell Automation is
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Throughout this manual we use the following notes to make you aware of safety considerations:

Identifies information about practices or circumstances
that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.

Identifies information that is critical for successful application and understanding of the product.

Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you:

• identify a hazard

• avoid a hazard

• recognize the consequence

Labels may be located on or inside the drive to alert people that dangerous voltage may be present.

Labels may be located on or inside the drive to alert people that surfaces may be dangerous temperatures.

PowerFlex Drives Configuration & Programming

Contents

Before You Begin ............................................................................................................................................................................ 5

About this lab .................................................................................................................................................................................... 5

Tools & Prerequisites ........................................................................................................................................................................ 6

Network Setup ................................................................................................................................................................................. 7

About the PowerFlex 525 Demo Box ............................................................................................................................................ 8

About the PowerFlex 755 DHQ Demo Box ................................................................................................................................... 9

Lab 1: Configuring the PowerFlex 525 AC Drive ....................................................................................................................... 10

Part 1: Using the HIM Keypad and Display ..................................................................................................................................... 10

Part 2: Utilizing EtherNet/IP™ and Connected Components Workbench™ Software .................................................................... 17

Lab 2: Configuring the PowerFlex 755 AC Drive ....................................................................................................................... 38

Part 1: Using the HIM Keypad and Display ..................................................................................................................................... 38

Part 2: Utilizing EtherNet/IP™ and Connected 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 HMI Application ....................................................................................................................................................... 102

Faceplate Operation ..................................................................................................................................................................... 102

Bonus Lab Exercise: Automatic Device Configuration (ADC) with the PowerFlex AC drives ............................................ 112

About Automatic Device Configuration (ADC) .............................................................................................................................. 112

Exploring the Setup of Automatic Device Configuration (ADC) .................................................................................................... 113

Demonstrating Automatic Device Configuration ........................................................................................................................... 118

Reset the System .......................................................................................................................................................................... 120

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Appendix: Overview of the DMAT ............................................................................................................................................. 121

Machine/Application/Device Module Relationship ........................................................................................................................ 122

Module Routine 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

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Before You Begin

Please review the following information before starting this lab.

About this lab

Learn the basics of drive configuration and programming using the PowerFlex 525 compact AC drive and the PowerFlex 755 AC
Drive. Attendees will configure these drives using the Human Interface Module (HIM), Connected Components Workbench
software and Studio 5000™ Logix Designer software. You will also try out AppView, a feature that provides specific parameter
groups for popular applications for the PowerFlex 525 AC Drive. The third lab exercise shows how Premier Integration™
enhances the use of PowerFlex AC drives with ControlLogix® and CompactLogix™ 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 “choose own adventure.” One can start with either Lab 1: PowerFlex
525 AC Drive Programming & Configuration or Lab 2: PowerFlex 755 AC Drive Programming & Configuration. Lab 3: Drive Add­On Profile with Drives and Motion Accelerator Toolkit is the premier integration of the drives using Studio 5000 Logix designer.

PowerFlex 525 AC Drive

Programming & Configuration

PowerFlex 755 AC Drive

Programming & Configuration

Premier Integration

Add-On Profiles with DMAT

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Tools & Prerequisites

Software programs required

• Studio 5000 Logix Designer v28.00

• PowerFlex 525 Add-On Profile v1.04.00

• PowerFlex 755 Add-On Profile v4.08.00

• Connected Components Workbench v8.01

• RSLinx Classic v3.74.00

• FactoryTalk View Studio v8.10

• RSLinx Enterprise v5.74.00

• Wizards v3.14.3

Hardware 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 located within the “C:\Users\labuser\Desktop\Lab Files\PF525 and PF755 - Basic HIM,
CCW, PI\Lab Files” folder.

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Hundreds – 0

Ones – 0

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

Network Setup

Ethernet Connections

Set IP Address of PowerFlex 755 to 192.168.1.30 by setting the IP address switches.

Tens – 3

The PowerFlex 525 Network Option module IP address will be set using the Keypad in Lab 1.

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About the PowerFlex 525 Demo Box

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About the PowerFlex 755 DHQ Demo Box

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Lab 1: Configuring the PowerFlex 525 AC Drive

Part 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 drive
 Reset the PowerFlex 525 drive to defaults
 Configure several parameters

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
 Supports multiple languages

 English

 French

 Spanish

 Italian

 German

 Portuguese

 Polish

 Turkish

 Czech

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Display and Control Keys

 AppView: Dedicated sets of parameters grouped 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

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Control and Navigation Keys

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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. Just read through the following.

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Reset Drive to Defaults

This is the beginning of the hands-on portion of 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.

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3. Press the Stop button to clear the fault from the drive.

4. Press the Esc button until you see zero speed on the keypad display.

5. Press the Select button and use the Up or Down arrows until you see the Basic
Program group on the HIM display.

6. Press the Enter or Sel button to enter the Basic Program group. The right digit of the last viewed
parameter 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. Once P053 is displayed, Press the Enter button. You will see “0 - Ready/Idle” scroll across the
display. Press the Up or Down arrows until you see “2 – Factory Reset”.

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9. Press the Enter button to confirm. The drive will fault with a scrolling message of “F048 – Parameters
Defaulted”. The picture below shows this.

10. Press the Stop button to clear the fault from the drive.

Configuring the 25-COMM-E2P, Dual Port EtherNet option module, IP Address Parameters

1. Take what you have learned about the keypad operation from the Reset Drive to Defaults section to make
the following Network Option Communication group parameter changes. Navigate to 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 settings to take effect, cycle power to the drive by using the Drive Power
selector switch located in the bottom left corner of the demo box. Turn the switch to the “OFF” position,
and then after the display of the drive goes dark, back to the “ON” position.

Continue on to the next exercise.

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Part 2: Utilizing EtherNet/IP™ and Connected Components Workbench™ Software

Connected Components Workbench programming and configuration software supports the Micro800™ controllers, as well as the
PowerFlex 4-class drives and PanelView™ Component graphic terminals for your small machine applications.

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
software.

You will see the following splash screen while the software loads, which may take a few moments.

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2. The main screen for the Connected Components Workbench software is shown below.

You may need to maximize 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.

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5. The lab’s preconfigured RSLinx driver will appear. Click on the [+] to expand the topic AB_ETH-1,
Ethernet. Click to highlight the “192.168.1.20, PowerFlex 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.

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Exploring Drive Parameters through Standard Parameter Groupings

1. Some useful tools for the PowerFlex 525 drive are included in the Connected Components Workbench
software, as shown below.

Take some time to explore them.

2. Select the ‘0 - PowerF lex 525’ tab, then click on the “Parameters” icon to 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
from defaults after clicking the button, it won't be added to the list until the view is refreshed.

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3. Make sure “All Parameters” is selected within the Group dropdown selection box and then click the “Show
Non-Defaults” button as shown below.

A progress window showing the upload will appear.

4. Once the upload has completed you will see the parameters window update to just show only the non­default 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 all of the 25-COMM-E2P parameters.

8. Close the Port 2 Parameters dialog box by clicking the

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9. Select the ‘0 - PowerF lex 525’ tab, then click ‘Parameters’. To make viewing and editing parameters even
simpler, you can enter a word or abbreviation into the filter value entry box. For example, type “Motor” into
the Filter Value entry box. Notice that it filters and only shows the parameters that have the word motor in
their parameter names.

Try some other examples such as “Dig”, “Speed”, or “10” and see the results.

Remember to clear/delete the entry field when finished.

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

11. 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.

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Exploring Drive Parameters with AppView™ and CustomView™ Groupings

The PowerFlex 525 drive has several AppView groupings that are tailored for a specific application to make the drive startup and
commissioning simpler. This reduces guesswork about which parameters you need to change, and all of the drive parameters
for that application are all in one convenient location.

1. Within the Group dropdown selection 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
“Edit Group” button.

3. The Edit Custom Group window will appear. Here you will be able to select and add parameters into a
nameable custom group. In this example, type in “ABC’s Group” in the Group Name box highlighted
below.

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4. Find the following parameters in the list and add them to “ABC’s Group”:

Parameter 30 - Language Parameter 43 - Minimum Freq
Parameter 31 - Motor NP Volts Parameter 44 - Maximum Freq
Parameter 32 - Motor NP Hertz Parameter 45 - Stop Mode
Parameter 33 - Motor OL Current Parameter 46 - Start Source 1
Parameter 34 - Motor NP FLA Parameter 47 - Speed Reference1
Parameter 35 - Motor NP Poles Parameter 62 - DigIn TermBlk 02
Parameter 36 - Motor NP RPM Parameter 63 - DigIn TermBlk 03
Parameter 37 - Motor NP Power Parameter 64 - 2-Wire Mode
Parameter 39 - Torque Perf Mode Parameter 65 - DigIn TermBlk 05
Parameter 40 - Autotune Parameter 76 - Relay Out1 Sel
Parameter 41 - Accel Time 1 Parameter 81 - Relay Out2 Sel
Parameter 42 - Decel Time 1

Once the parameters have been added, click the “OK” button to download this CustomView group to the drive.

You can also select/highlight multiple parameters then click the “Add - >” button. This makes adding
parameters go a lot faster.

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5. Notice how the parameter entries from above are all now in the ABC’s Group CustomView for easy viewing
and editing of the parameters.

Close the ‘Parameters’ dialog box 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.

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3. Click the “Next >” button to proceed with exploring the startup wizard.

4. Below is the Reset Parameters page. Here you have 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”.

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5. When the Confirmation window appears, verify that you made the correct choice and click the “Yes” button.

The drive may 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…

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7. On the next three pages, verify and if needed, modify the parameters according to the following
screenshots. At the end of each page, remember to click the “Next >” button to proceed to the

next page.

 Motor Control Page

 Motor Data Page (changes required)

 Feedback Page

 Stop / Brake Mode Page

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8. The next page is for the Direction Test. If desired, you may skip the Direction Test by clicking the “Next >”
button and move onto the next numbered step in this manual. To continue with the Direction Test, follow
the steps below.

Press the Stop button to Clear Faults if the drive is faulted. The button is shown below.

Press and hold the Jog button to run the Direction Test. The button is shown below.

Note: If the following window appears, click the “Yes” button.

If the motor rotation is in the correct direction, click on the “Yes” radio button.

Proceed to the next test by clicking the “Next >” button.

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9. The next page is for the AutoTune. If desired, you may skip the AutoTune by clicking the “Next >” button
and move onto the next numbered step in this manual. To continue with the AutoTune, follow the steps
below.

Click on the “Rotate Tune” button highlighted below to initiate the AutoTune Test. It may take up to a minute to complete
after pressing the button.

Once finished, you will see the “Test Completed: Yes” result.

Proceed onto the next page by clicking the “Next >” button.

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10. On the next several pages, verify and if needed, modify the parameters according to the following
screenshots. At the end of each page, remember to click the “Next >” button to proceed to the next page.

 Ramp Rates / Speed Limits

 Speed Control

 EtherNet/IP

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 Digital Inputs (changes required)
 We want to demonstrate control of the drive using the Keypad or from switches in the demo box wired to the PowerFlex

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.

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 Relay Outputs (changes required)

• Opto Outputs

 Analog Outputs

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11. After stepping through the previous pages to the Pending Changes page, you can review a summary of the planned

programming changes you have made to the PowerFlex 525 drive.

Make sure all the pages have the check mark ( ) to the left of the page name / icon.
Click the “Finish >>” button to accept pending changes.

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12. The main PowerFlex 525 drive window will be present. Click the “Reset” button for all of the new parameter settings

to take effect. Some settings require a drive reset to be implemented.

A window will appear confirming that you would like to reset the device.

Click the “OK” button. You will hear the PowerFlex 525 drive cycle power and the HIM Keypad display will turn off and
on before scrolling the drive information.

The reset happens quickly. You may see the following screen appear If it does, click the “OK” button.

13.

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. Select the “No” button for each.

15. The configuration of the PowerFlex 525 is complete. At this point, we will be using the startup settings to run the motor.

16. Keeping in mind that you now control the drive from two sources: the push buttons and potentiometer of the drive, and

the selector switches; attempt to run the drive.

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17. You should start with the selector switches in the following position: DI1 in this position will select t he drive Keypad to

control the drive.

18. With the buttons on the PF525: use to start the drive, 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 next exercise

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Lab 2: Configuring the PowerFlex 755 AC Drive

Part 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 755 drive
 Reset the PowerFlex 755 drive to factory defaults
 Set the motor control mode and enter motor nameplate data
 Set the speed 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 the ways to perform an Assisted Startup on the PowerFlex 755 is using the Startup routine in the H.I.M. The following
steps will lead you through that:

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1. Access the Status screen which is displayed on HIM PowerUp. Press STOP button to clear fault

2. Press the ‘Folders’ button on the HIM keypad. The button is located on the bottom row of the HIM Keypad
(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 ‘MEMORY’.

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ESC INFO

Port 00 Set Defaults

Host and Ports ( Preferred)

This Port Only

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

4. Use the down arrow key to highlight ‘Set Defaults’ if necessary and press the Enter key located in the
center of the HIM keypad to make this your selection.

5. The screen which follows after completion of the previous step is shown. Use the down arrow key to highlight
‘This Port Only’. Press the Enter key located in the center of the HIM keypad to make this your selection.

6. Use the soft key labeled ‘ALL’ to reset default all parameter settings in the Drive.

7. Use the ‘CLR’ soft key to acknowledge and clear the ‘Module Defaulted’ fault.
Press the ‘Enter’ soft key.

8. Press the ‘Folders’ button on the HIM keypad again to access the Folders Menu.

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START UP

Begin Start Up

PowerFlex 755 Startup

Start-Up consists of several
steps to configure the drive.
Press ENTER

ABORT ENTER

9. Now use the left or right arrow keys to scroll through the different folders, to locate the folder called
‘START UP’.

10. The first item listed in the ‘START UP’ folder is ‘Begin Start Up’ and this is highlighted 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.

 Note: You can always use the ESC soft key to return to a previous step.

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PowerFlex 755

Startup

ABORT ENTER

General Startup

Appl Specific
Exit Startup

ABORT ENTER

General Startup

Motor Control

Motor Data
Feedback

Main Menu

Limits

Complete these steps in order:

This section selects the type
of Motor Control the drive will
use.
Press ENTER

ABORT ENTER

Startup
Motor Control

12. Pressing the ‘ENTER’ soft key in the previous step has led you to a new screen, which allows you to select the type of
startup you wish to perform. For this lab session, we will choose ‘General Startup’. This is highlighted by default. Press
the ‘ENTER’ soft key located on the top row of the HIM keypad to make this your selection.

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’.

14. The introduction screen provides information about the ‘Motor Control section. Press the ‘ENTER’ soft key to continue.

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ABORT ENTER

General Startup

Motor Control

Motor Data

Feedback

Main Menu

Limits

Complete these steps in order:

15. Pressing the ‘ENTER’ soft key in the previous step leads you to a screen which lists the available motor control modes
in the PowerFlex 755. For this lab session, we will choose the Sensorless Vect mode. Use the scroll down or
scroll up arrow soft keys to select ‘Sensorless Vect’. Press the ‘ENTER’ soft key to make this your selection.

Entering Motor Nameplate Data

16. After selecting the motor control mode in the previous step, you are directed back to the General 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.

17. Pressing the ‘ENTER’ soft key in the previous step has led you to the ‘Startup Motor Data Entry’ screen. The first
information you will provide is the Motor Nameplate (NP) Volts. The Motor in the demo is rated for 230 V. This should
be the default value for this parameter. Press the ‘ENTER’ soft key to confirm your input and move to the next screen.

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Edit Motor NP Volts

230.00 VAC

0.10

264.50

Startup
Motor Data Entry

Def

Min
Max230.00

EXP

ABORT ENTER

Startup

HP

kW

Motor Data Entry

Select type of power units
Shown on motor nameplate:

18. The next information you need to provide is the Power Units. By default the value of the parameter should be set to
‘HP’. Press the ‘ENTER’ soft key to confirm your selection and move to the next screen.

19. You will now be required to input the Motor 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 of the
soft keys (top row of the HIM keypad) is now a ‘decimal point’ button. Use the ‘decimal point’ soft key button and the
appropriate number keys to input a value of ‘0.033’. Press the ‘ENTER’ soft key to confirm your input and move to the
next screen.

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Edit Motor NP Power

Startup
Motor Data Entry

EXP

Def 1

.

00 Max

Min

2000.

00

0.

01

1

.

00 HP

Edit Motor NP Power

Startup
Motor Data Entry

EXP

Def 1.00 Max

Min

2000.00

0.01

0.03 HP

Edit Motor NP Amps

0. 22 Amps

0.00

42.00

Startup
Motor Data Entry

Def

Min
Max2.90

EXP

20. You will now be required to input the Motor Nameplate (NP) Amperes. The Motor in the demo is rated for 0.22 amps.
Use the ‘decimal point’ soft key button and the appropriate number keys to input a value of ‘0.22’. Press the ‘ENTER’
soft key to confirm your input and move to the next screen.

21. You should be in the ‘Edit Motor NP Hertz’ screen. The Motor in the demo is rated for 60 Hz. The Default value should
be ‘60’ Hz. Press the ‘ENTER’ soft key to confirm your input and move to the next screen.

22. You will now be required to input the 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 selection for this lab session. Press the
‘ENTER’ soft key to confirm this and move to the next screen.

24. You should be in the ‘Edit Motor Poles’ screen. The Motor in the demo is a 4 Pole motor. By default, this parameter
value is set to a value of ‘4’. Press the ‘ENTER’ soft key to confirm this as your selection and move to the next screen.

25. You will now be required to input the Speed Units. For this lab we will use ‘RPM’ for our Speed Units. Use the scroll
down or scroll up arrow soft keys to select ‘RPM’. After this setting has been selected, press the ‘ENTER’
soft key to confirm this and move to the next screen.

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Edit Speed Units

RPM

1
0
1

Startup
Reference Selection

Def

Min
Max0

ABORT ENTER

General Startup

Motor Control
Motor Data

Main Menu

Limits

Complete these steps in order:

Feedback

Setting the Speed Feedback Device

26. With the completion of the previous step, you have finished inputting the Motor Nameplate data and 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.

27. Select ‘Open Loop’ as we do not have an encoder on board the Drive.

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ABORT ENTER

General Startup

Motor Control
Motor Data

Feedback

Main Menu

Limits

Complete these steps in order:

ABORT ENTER

General Startup

Tests

Motor Data
Feedback

Main Menu

Limits

Complete these steps in order:

Setting the Speed Limits

28. The previous step was the last step in configuring your feedback device. You should now have been directed back to
the General Startup Main Menu. Configuring the limits is the next step in the Startup routine. Press the ‘ENTER’ soft
key to access ‘Limits’ section.

29. For this lab session, we will be making the following changes in the ‘Limits’ section. Use the number keys to input the
values listed for each item and press the ‘ENTER’ soft key to move forward to the next screen. After the four values
have been entered, 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. Press the ‘ENTER’ soft key to access ‘Tests’ section.

31. There are two tests which are part of the Startup Routine. You will perform these tests in the next few steps. You will
run the Direction test first. The ‘Direction Test’ list item should be highlighted by default. Press the ‘ENTER’ soft key

to make this your selection. Press the Start key to start the motor.

T

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Startup
Direction Test

Yes

No

Is the direction of rotation
forward?

Startup
Direction Test

Change fbk wires

How would you like to fix the
motor polarity?

Automatic Change

Startup
Direction Test

Press STOP
Startup will then automatically
change rotation as if motor
leads were reversed

32. The next screen asks the question ‘Is the direction of rotation forward?’ To demonstrate the ability of the PowerFlex
755 to electronically swap motor leads to change motor direction, let us choose ‘No’ as the answer to this question.

Use the down arrow key to select and highlight ‘No’ and press the Press the ‘ENTER’ soft key.

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.

34. The screen that follows asks you to stop the drive so this change in direction, initiated in the previous step, can take
place. Press the ‘STOP’ key to stop the drive.

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Startup
Direction Test

Press STOP
Startup will then automatically
change feedback device
polarity

Startup
Direction Test

Is the direction of rotation
forward?

No

Yes

35. Follow the direction on the next screen which asks you to ‘START’ the drive. You can start the drive and by using the
START key.

36. The next screen asks the question ‘Is the direction of rotation forward?’ and requires confirmation that the changes to
direction are acceptable. If the motor is running forward, select ‘Yes’ by pressing the ‘ENTER’ soft key. If motor is
running reverse, repeat

37. As required by the following screen, press the STOP key to stop the drive.

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?’

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 key to select the ‘Auto tune’ Test.
Read the important information on the screen and press the ‘ENTER’ soft key.

42. Pressing the ‘ENTER’ soft key in the previous step has directed you to the ‘Select the tuning mode’ screen. For this lab
session, we will perform a rotate tune on the demo motor. Select the default highlighted option ‘Rotate Tune’ by
pressing the ‘ENTER’ soft key.

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Startup
Auto Tune

Test in progress:
Stator Resistance

Please Wait
Press STOP to abort test

Startup
Auto Tune

Test in progress:
Flux Current

Please Wait
Press STOP to abort test

43. As directed by the HIM screen information, press the START key to start the ‘Auto tune’ Test. Notice the
changing information on the HIM (as the different parts of the Auto tune tests are completed).Wait till the test is
completed.

44. The completion of the test is indicated by the ‘Test Completed Successfully’ screen. Press the ‘ENTER’ soft key.

45. Pressing the ‘ENTER’ key in the previous step has directed you back to the ‘Motor Test Menu’. Use the ‘ENTER’ soft
key to select ‘Done’ in the ‘Motor 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 session. Press the ‘ENTER’ soft key to confirm and save your selection.

48. You should be on the ‘speed reference source’ selection screen. Use the down arrow or up arrow
keys to highlight ‘Analog Input’ as your Speed Reference source. Use the ‘ENTER’ soft key to make this your
selection.

49. In the window ‘Select Port to Use’ that appears following the previous step, use the down arrow or up arrow

keys to highlight ‘Port 07 I/O module 24V’. Use the Enter key to make this your selection.

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50. Use the down arrow and up arrow keys, if necessary, to highlight ‘Par 0050 Anlg In0 Value’. Use the
Enter key to make this your selection. Press the ‘ENTER’ soft key to confirm and save your selection.

51. The next few steps will configure the Analog Input you chose as Speed Reference. For this lab session we will use the
0-10V potentiometer (labeled 0-10VDC IN 0) on the demo as our Analog Input speed reference. Pressing the ‘ENTER’
soft key in the previous step has led you to the first item required to configure the Analog Input. You should be in ‘Edit
Anlg In0 Hi’ screen. Press the ‘ENTER’ soft key to accept the default value of ‘10.000’ Volt.

52. In the ’Edit Anlg In0 Lo’ screen that follows, press the ‘ENTER’ soft key to accept the default value of ‘0.000’ Volt.

53. In the next few screens input these values:

 ‘Speed Ref A Anlg Hi’= 1600 RPM
 ‘Speed Ref A Anlg Lo’ = 0 RPM

Press the ‘ENTER’ soft key.

54. You should be in the ‘Startup / Stop Config’ screen now, press the ‘ENTER’ soft key to accept the default selection of
‘Ramp 1’ to be used as ‘Stop Mode A’.

55. Pressing the ‘ENTER’ key in the previous step has directed you to the screen to configure the ‘Bus Reg Mode A’.
Select the default of ‘Adjust Freq 1’ using the ‘ENTER’ soft key.

56. Following the step to set bus regulation you will now set Ramp (Accel and Decel) times. In the ‘Edit Accel Time 1’
screen, use the appropriate 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 highlighting it using the

down and up arrow keys and then using the ‘ENTER’ soft key to confirm and save your selection.

Configuring the Inputs and Outputs

59. Completing the previous step successfully has led you to the ‘General Startup Main Menu’ with the item ‘I/O’
highlighted. Press the ‘ENTER’ soft key to enter the ‘I/O’ section.

60. You should be in the ‘Start Stop I/O’ screen now. The first item to configure on this list is ‘Start Stop & Dir’. Press the
‘ENTER’ soft key to enter this section. Read the Introductory screen to this section and press the ‘ENTER’ soft key to
continue.

61. The next screen requires you to answer the question ‘Will a Digital Input be used as a START Source? Select ‘Yes’
using the down and up arrow keys and then using ‘ENTER’ soft key to confirm and save your

selection. We will use the green push button labeled ’IN 1’ in the demo as our Start Source in a later step.

62. The next screen will ask the question ‘Is Reverse required from a digital input?’ Select ‘Yes’ using the down
and up arrow keys and then using ‘ENTER’ soft key to confirm and save your selection. We will use the switch

labeled ’IN 2’ in the demo as forward/reverse in a later step.

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63. Select ‘3 wire’ as your choice for the question ‘Enter Choice for the control method’.

64. In the ‘Select Port To Use’ window use the up and down arrow keys to highlight ‘Port 07 I/O Module 24V’ Press the
‘ENTER’ soft key to make this your selection.

65. In the ‘Param to Use’ window Press the Enter soft key to select

66. First, you will select the bit/Digital Input you want to use as your START. We are going to use the green push button
labeled ‘IN 1’ as our start input. To do this scroll to Bit 01 Input 1 and press the Enter soft key.

67. Repeat steps 66 and 68 to select the red push button labeled ‘IN 0’ as your Stop switch (Bit 00 Input 0) and the
selector switch labeled ‘IN 2’ as your Forward/Reverse switch (Bit 02 Input 2) in that order.

68. Back in the ‘Start Stop I/O’ menu screen. Scroll down to ‘Analog Outputs’ and select ‘ENTER’.

69. In the ‘Select Port To Use’ window use the up and down arrow keys to highlight ‘Port 07 I/O Module 24V’ Press the
‘ENTER’ soft 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 all we will configure in this section so use the

down arrow keys to scroll down to the last item on the list ‘Done’. After ‘Done’ is highlighted, use the ‘ENTER’

soft key to make this your selection.

76. You should now be back in the General Startup Main Menu screen .you have finished with the Startup routine steps
required for this lab session. Select ‘Done’ using the ‘ENTER’ soft key to exit out this screen.

77. Select ‘Exit Startup’ using the ‘ENTER’ soft key to exit out of the Startup routine.

78. You can now test your drive to perform the functions you configured during the startup routine namely, Start using the
green push button IN 1, Stop using the red push button IN 0, change direction using IN 2 and provide speed reference
using the ‘0-10VDC IN 0’ pot.

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Part 2: Utilizing EtherNet/IP™ and Connected Components Workbench™ Software

Connected Components Workbench includes user-interface configuration tools for Micro800™ controllers, PowerFlex® drives, a
Safety Relay device, PanelView™ Component graphic terminals, and serial and network 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 following splash screen while the software loads, which may take a few moments.

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8. The main screen for the Connected Components Workbench software is shown below.

You may need to maximize 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.

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11. The lab’s preconfigured RSLinx driver will appear. Click on the [+] to expand the topic AB_ETH-1,
Ethernet. Click to highlight the “192.168.1.30, PowerFlex 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.

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Exploring Drive Parameters through Standard Parameter Groupings

13. Some useful tools for the PowerFlex 755 drive are included in the Connected Components Workbench
software, as shown below. 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.

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16. Observe the multiple tabs available for each optional module (card) in the drive. These tabs indicate the function of the
module (card) and display important information, such as voltage and amp ratings, series, revision, 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 peripheral ‘0-PowerFlex 755’.

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19. Click on the “Parameters” icon to view the PowerFlex 755 drive parameters 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.

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This is a read-only parameter that displays the value of the DC Bus Volts. This value changes as the DC Bus Volts varies,
and you can see that here. Click Cancel.

Scroll down even further to Parameter 535 [Accel Time 1], and then double-click on this parameter to view and edit it

This is a writeable parameter that determines the acceleration rate it takes to go from 0 Hz to Parameter 27 [Motor NP
Hertz] or Parameter 28 [Motor 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
were changed from their default setting.

This button only updates the set of parameters shown based on the upload. When a parameter changes
from defaults after clicking the button, it won't be added to the list until the view is refreshed.

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20. Make sure “All Parameters” is selected within the Group dropdown selection box and then click the “Show
Non-Defaults” button as shown below.

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 non­default 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.

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23. To make viewing and editing parameters even simpler, you can enter a word or abbreviation into the filter

value entry box. For example, type “motor” into the Filter Value entry box. Notice that it filters and only
shows the parameters that have the word motor in their parameter names.

Try some other examples such as “inp”, “torque”, or “535” and see the results.

Remember to clear/delete the entry field when finished.

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24. Under the Group dropdown selection box, you can scroll through the different drive parameter groups.

25. Select “Speed Ramp 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.

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PowerFlex 755 Drive Start-Up Wizard

27. Click on the Wizard Browser icon to launch the Wizard Browser and display the available wizards.

The PowerFlex 755 Startup Wizard is similar to performing the HIM Assisted Startup. Configuration parameters that are
common to most applications are displayed in text / graphic forms and presented in a sequential step-by-step process.

The DPI/DSI Tech Support Wizard is used to collect information for a remote support person to help troubleshoot a problem.
Drive and peripheral information such as series and revision 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 future
and can be added to Connected Components Workbench at any time. New wizards will be posted on the AB Drives Web
Updates page for free download:

http://www.ab.com/support/abdrives/webupdate/index.html

 Note: The same wizards also work with DriveTools SP v6.02 (or higher), Logix Designer, and RSLogix 5000 v16 (or higher)

with Drive AOP 3.01 (or higher)

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28. Select the PowerFlex 755 Startup Wizard and click Select.

The wizard will first upload the parameters for each of the wizard pages.

29. The first step in the wizard is the 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.

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In the confirmation window, click Yes.

Observe the on screen confirmation of the parameters being reset.

Click Next > to continue viewing the System Time 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

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Click Next

to get to the Motor Data step of the wizard.

32. The Motor Data step is 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

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Click Next > to the Stop Mode step of the 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.

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34. The Direction Test step is next. It helps you determine if the motor is rotating in the proper direction for your
application. No selections need to be change on this screen.

• Note: If the drive is faulted, click on to clear the fault.

Direction tests are 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 Test Passed status as well as adding the Change Direction option.

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Click Next > to the AutoTune step of the wizard.

35. The AutoTune step is next. This step is where you can use the automatic tuning algorithms (AutoTune). When
running these algorithms, the drive energizes the motor and makes measurements, which are used to make parameter
settings.

AutoTune tests are not needed for this 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 the Ramp Rates / Speed Limits step of the wizard.
 Note: Clicking < Back, Next >, or leaving step by any means will abort the test.

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36. The Ramp Rates / Speed Limits step is next. Set the following values:

 Max Forward Speed: 60 Hz
 Min Forward Speed: 0 Hz
 Min Reverse Speed: 0 Hz
 Max Reverse 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].

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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.

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Click Next > to continue, viewing the sequential process, continue to click Next > until you reach the Start / 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]

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Click Next > to the Other Digital Inputs step of the wizard.

40. The Other Digital Inputs step is next. No changes need to be made here.

Click Next > to continue to ‘Analog Output Port 7’  ‘Analog Out 0’

 Note: There are other digital 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 Pending Changes step of the wizard.

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43. The Pending Changes step is next, and last. The purpose of this step is to verify all of the changes you made in the

wizard, and then apply the changes to the drive. The below screen is for your reference, and 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 inputs to spin the motor.

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Using the Control Bar Tool

45. Change Parameter 301 [Access Level] to Expert 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.

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The speed reference was selected earlier to be Port 7 [I/O Module 24V] Parameter 50 [Anlg In0]. To allow the control bar to
have control of the speed reference, 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.

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Using Off-line Files

This feature allows you to save your drive configuration to a computer. It is useful for several reasons:

 You can use the configuration if you replace the drive or install an identical one
 You can use the configuration to troubleshoot the drive if it begins to malfunction because the settings have changed

Uploading and Saving the Drive’s Configuration to a PC

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 from the drive

53. The following window should come up showing each port’s parameter is uploading.

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

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55. Disconnect from the drive and select No when ask to upload values from online to project.

56. You should notice that your saved file has an .iuux extension.

Downloading a saved Configuration CCW file to 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 , click the button.

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62. Wait as CCW gathers port information.

63. Select the Error 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.

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66. During the Download process you may receive warning messages. If you see this “Data Out of Range” message, Click

the Blue Magnifying Glass button…

…A dialog 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.

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Lab 3: PowerFl ex Drives Add-On Profile with Drives and Motion Accelerator Toolkit.

This section will provide a preview of the PowerFlex Drives Add-On Profiles as well as the Drives and Motion Accelerator Toolkit
Add-On Instructions and Faceplates for the PowerFlex 525 and PowerFlex 755 drives.

About Integrated Drive Profiles and Premier Integration

Integrated Drive Profiles are designed to save system development time and to make systems easier to maintain.
Testing of skilled engineers configuring drives in a timed, side-by-side comparison, Integrated Drive Profiles in RSLogix 5000

and Studio 5000 Logix Designer software can reduce drive system development time by as much as 70% compared to traditional
configuration. This is achieved by:

 Providing one software tool to configure the entire controller and drive system.
 Configuring both controller and drive network connections from a single location – eliminating I/O mismatch errors.
 Allowing the dynamic selection of drive parameters transmitted as network I/O – communicating only what is needed for the

application.

 Auto-generating descriptive tag names – eliminating the need to enter individual tag descriptions.
 Auto-generating respective tag data types – eliminating the need to convert from one data type to another.
 Saving all drive configurations in the project file and in the controller – providing a single source of drive configuration data.
 Providing Copy & Paste capability when creating additional duplicate drives – reduces errors in configuration with systems

containing multiple identical drives.

 Using the same easy-to-use drive configuration Wizards in the Connected Components Workbench, DriveTools SP, and

DriveExplorer software packages.

Systems using the Integrated Drive Profiles in RSLogix 5000 and Studio 5000 Logix Designer software are also easier to
maintain:

 Drive diagnostics, faults, alarms and event information is integral to RSLogix 5000 and Studio 5000 Logix Designer software.
 Drive Tech Support Wizard can be run from RSLogix 5000 and Studio 5000 Logix Designer software to collect all pertinent

information about a drive, its peripherals, various software components, and PC operating system.

 Drives can be flash updated from RSLogix 5000 and Studio 5000 Logix Designer software.
 Having a single repository of drive configuration data in the controller project file reduces downtime by speeding drive

replacement.

Integrated Drive Profiles are "Add-On Profiles", independent of particular releases of RSLogix 5000 and Studio 5000 Logix
Designer software. Many are backward compatible to work with previous versions of the programming software as well, helping
to prevent obsolescence of the controller when newer drives are available.

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Exploring the Add-On Profile for the PowerFlex 525 Drive

1. Start the program. Double-click the Studio 5000 software 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.

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Lab files are located within the “C:\Users\labuser\Desktop\Lab Files\PF525 and PF755 - Basic HIM,
CCW, PI\Lab Files” folder.

The file will 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”.

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The Add-On Profile for the PowerFlex 525 drive in the Logix Designer software provides a common look-and-feel to the
Connected Components Workbench software. This 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.

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.

= Creates device database from online drive to add new revisions and configurations

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The following screenshot is for the PowerFlex 525 Embedded Ethernet communication. For this lab we are

then clicking ‘Properties’ and selecting the ‘Communications’ tab.

= Reset device data to factory defaults
= Print

If you forget each button’s purpose, hold your cursor over them to display a tooltip with their function.

7. Click on the “Communications” tab.

using the 25-COMM-E2P module in Port 2 for communication.
You can view a similar Properties dialog box for the 25-COMM-E2P by selecting the ’2 - 25-COMM-E2P’ tab,

On this tab, you can configure the Ethernet communication settings for the drive. This includes setting a static IP address or
configuring the drive for BOOTP or DHCP.

8. Click on the “Import/Export” tab.

From this tab, you can import or export the drive configuration file as either a *.PF5 (PowerFlex 520 Series USB) or *.IUUX
(CCW Device) file type. Using 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 or *.CSF files.

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9. Click on the [X] in the upper right hand corner to close the Properties window.

10. Now let’s look at the PowerFlex 755. In the Controller Organizer, double-click on the “PowerFlex 755-
EENET PF755_Drive”.

11. From the Module Properties window, click on the “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 tool bar for the PowerFlex 755 can be described as follows:

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13. Observe the multiple tabs available for each optional peripheral in the drive. These tabs indicate the
function of each module and display important information such as: port, voltage and amp ratings,
series, and revision. Click on each port peripheral to review.

NOTE: Your window may be different from pictured image as demo boxes 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 from the online drive or download database files from the web
 Perform a full or Partial Drive Match
 Configure the input and output datalinks

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15. Close the PowerFlex 755 Module Properties window and reopen the PowerFlex 525 Module Properties
window. Navigate to the Drive tab.

16. Click on the “Parameters” button. This should look familiar- just like the Connected 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 the Module Definition.

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18. 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:

 Select the Drive Rating, set the Revision of the drive firmware, and set the Electronic Keying
 Create database files from the online drive or download database files from the web
 Configure the input and output datalinks

The Module Definition window provides the ability to configure up to four words of Input Data and four words
of Output Data to be passed through the embedded Ethernet connection. 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 as Stop, Start, Forward,
Reverse, and Clear Faults.

The “FreqCommand” word contains the commanded reference value for the drive to run.

Datalinks

Datalinks are pointers to drive parameters. Instead of offering fixed I/O assemblies where what-you-see-is­what-you-get, our drive I/O assembly is dynamic and gives the programmer the ability to pick and choose the
desired parameters to communicate as network I/O.

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19. To configure the datalinks, you would select the parameters from the dropdown selection 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.

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Taking Advantage of Having the Drive in the Controller Organizer

When your application requires more than one drive, you can save time with Studio 5000 for configuration. Within the Controller
Organizer, you can duplicate the PowerFlex 525 drive or the PowerFlex 755 drive on the Ethernet network as many times as
needed by using the Copy and Paste features. All of the node information is copied, including the drive parameter settings. All
you need to do is change the IP address, and give the device a unique name. Integrated Drive Profiles are not only easy to use;
they also allow larger systems to be designed faster.

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 configuration data gets stored? The drive configuration data for each node is
actually stored in your Logix Designer project! It also resides in the controller after the project is downloaded.
This provides a convenient local resource for a node’s configuration settings if the drive needs replacing.
Just connect to the controller, open the drive’s AOP, and download the configuration!

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4. In addition to storing the configuration data in the controller, the controller manages the communications to

the drive with convenient tag-b ased addres sing. Double-click on the “Controller Tags” icon under the
“Controller PowerFlex_Lab” folder.

The Monitor Tags window will appear.

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 the Input Datalinks). Note
that the proper data types are automatically used for every tag.

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6. Now expand the “PF525_Drive:O” tag to view the output tag names.

Descriptive tag names have been created for the drive again. The Logic Command bits (BOOLs) are clearly defined as well
as the “FreqCommand” value for applying a reference to the drive. The proper data types are automatically used for every
tag.

7. Close the Studio 5000 Logix Designer project.

Click “No” when prompted to save changes to the project.

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Downloading the Project

1. Open the PowerFlex_Lab project. Click 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.

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4. Click on the “Drive” tab.

5. Click the “Download” button.

The Connection Browser window will appear.

6. Expand the “AB_ETH-1” Ethernet driver and sele ct 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”.

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8. For a brief moment, you will see a downloading progress bar while the parameter settings are being sent to 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.

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11. Click the “OK” button to clo se the Module Properties window,

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.

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16. Click “OK”.

17. You will be asked to select a device to download. Please select ALL devices.

If 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.

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21. Verify that the node labeled “192.168.1.10, 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

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23. Put the controller in “Run” mode. One way to do this is by clicking on the mode drop-down arrow and select
“Run Mode”.

24. When prompted to confirm swi tching the controller 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.

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