PowerFlex Drive Academy

Lab Exercise: Drive Programming , PowerFlex® 525

Instructor: Alan Roycroft

(Please do not remove from the room)

 Table of Contents
TABLE OF CONTENTS _________________________________________________________________ 3
INTRODUCTION TO POWERFLEX 525 COMPACT AC DRIVES ______________________________________ 4
PRODUCT PRESENTATION ___________________________________________________________ 4
ABOUT THIS HANDS-ON LAB ________________________________________________________ 15
LAB M ATERIALS _________________________________________________________________ 15
DOCUMENT CONVENTIONS _________________________________________________________ 17
LAB#1: DRIVE OVERVIEW _____________________________________________________________ 18
ABOUT THIS LAB ________________________________________________________________ 18
UNDER THE HOOD ________________________________________________________________ 18
LAB#2: USB FUNCTIONALITY __________________________________________________________ 19
ABOUT THIS LAB ________________________________________________________________ 19
BEHIND THE CONTROL MODULE ______________________________________________________ 19
USB FUNCTIONALITY _____________________________________________________________ 20
LAB#3: USING THE HIM KEYPAD & DISPLAY _______________________________________________ 23
ABOUT THIS LAB ________________________________________________________________ 23 HIM
KEYPAD & DISPLAY ___________________________________________________________ 23
CONFIGURE PARAMETERS __________________________________________________________ 27
LAB#4: UTILIZING ETHERNET/IP AND CONNECTED COMPONENT WORKBENCH™ _____________________ 29
ABOUT THIS LAB ________________________________________________________________ 29
CONNECTING TO THE DRIVE WITH CONNECTED COMPONENT WORKBENCH ______________________ 29
FAULT QUEUE ___________________________________________________________________ 31
SEARCH AND MODIFY DRIVE PARAMETERS _____________________________________________ 32
EXPLORING DRIVE PARAMETERS VIA PARAMETER GROUPINGS, APPVIEW™ AND CUSTOMVIEW™ _____ 33
PROTECTING PARAMETERS _________________________________________________________ 37
POWERFLEX 525 START-UP WIZARDS ________________________________________________ 38
LAB#5: POWERFLEX 525 DRIVE ADD-ON PROFILES __________________________________________ 47
ABOUT THIS LAB ________________________________________________________________ 47
USING STUDIO 5000 WITH THE POWERFLEX 525 DRIVE ADD-ON PROFILE _______________________ 47
LAB#6: AUTOMATIC DEVICE CONFIGURATION _______________________________________________ 58
ABOUT THIS LAB ________________________________________________________________ 58
CONFIGURE ADC ________________________________________________________________ 58
APPENDIX A: DMAT QUICK INTRODUCTION ________________________________________________ 61
APPENDIX B: DETAILED OVERVIEW OF THE DMAT(FOR REFERENCE) ______________________________ 66
M ACHINE/APPLICATION/DEVICE MODULE RELATIONSHIP ___________________________________ 66
MODULE ROUTINE OVERVIEW _______________________________________________________ 67
M ACHINE MODULE _______________________________________________________________ 69
M ACHINE STATE DIAGRAM _________________________________________________________ 70
APPLICATION MODULES ___________________________________________________________ 75
DEVICE MODULES ________________________________________________________________ 76

Introduction to PowerFlex 525 Compact AC Drives

Product presentation
Please review the following slides carefully as they cover the basic product overview and serve as the basis for the
hands-on lab.

PowerFlex 525 are the latest addition to the PowerFlex Drives portfolio. They are also referred to as next generation
Compact AC Drives.

• The PowerFlex was designed to meet the needs of our customers.

• Extensive feedback was given during the Voice of Customer interviews. A number of key points are listed below:
• The drive needs to be designed with small footprint  Panel size is important.
• Different mounting options are required  Sometimes it’s good if drives can be mounted horizontally.
• The market is demanding permanent magnet motor control  Open loop permanent magnet motor control for
energy savings.
• The drive needs to support higher ambient temperatures  Certain regions in the world are warmer than others.
• Machine Safety is important  Safe Torque-Off shall be integral to the drive.
• Ease of Use  Not everyone is a drives specialist, so the products need to be user friendly.
• Communication and integration into the Logix controller environment  Standard Ethernet communication options
and drive Add-on Profiles for Studio 5000 (formerly RSLogix 5000).

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• Looking at the PowerFlex 525 features and performance, we can position this product slightly above the
contemporary PowerFlex 4-class family. (PowerFlex 40/40P).
It is, however not covering the full functionality of the PowerFlex 70 as the PowerFlex 525 will not allow
genuine torque control.

• Considering the power range of up to 22 kW normal duty, the PowerFlex 525 exceeds the range of the current
general purpose 4-class drives (up to 11kW).

• None of the contemporary products will be made obsolete within the next years.
• A wide range of voltage and power ratings are available in single and three-phase versions.

• For the EMEA market we will mostly use the versions with integral filtering:
•The integral filter allows EMC compliance for Category C3 (Formerly Class A filter) up to 20m of motor
cable length.
•Category C1 (formerly Class B filter / domestic environments) can be achieved by using an external piggy
back mounted EMC filter.

• To accommodate environments with poor mains supplies (i.e. with voltage dips and sags), the input voltage
tolerance has been increased from -15% to +10%.

• Similarly to the PowerFlex 4-Class products, the drives rated 7.5 kW or below are all heavy duty rated. That means
they can handle 150% overload for 1min (every 10 min) and 180% for 3s (every minute).

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• The drive comes in five Frame sizes (A to E), depending on the power rating.

• The footprints of PowerFlex 525 are smaller than those of PowerFlex 40/40P. The depth has increased slightly but
this generally doesn’t matter as it doesn’t affect panel space.

• The drives can be zero stacked (mounted side by side without clearance) and the mounting clearances (top and
bottom) have also been reduced compared to the current PowerFlex 4-Class products. Less clearance means more
drives per given panel space.

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• The temperature range has been significantly increased. PowerFlex 525 can handle an ambient temperature up to
60° C with some power derating (stated in the user manual), and even up to 70° C with an additionally installed fan
kit for the control circuitry.

• With the optional fan kit installed, the drives can be mounted horizontally.

• The fan kit must be separately supplied with 24VDC, except for frames D an E, where they can be fed from the on-
board power supply.
• By default, PowerFlex 525 are equipped with an integral Ethernet/IP port and a DSI (Drive Serial Interface).

• Other communications options are:

• Dual Port Ethernet/IP with embedded switch technology and DLR (Device Level Ring) support. The IP address can
be assigned via BOOTP/DHCP, rotary switches or a HIM keypad (Local or remote).
• DeviceNet card.
• Profibus card.

• Drive AOP (Add-on Profiles) have been created for the versions with Ethernet/IP to facilitate the integration into
Studio 5000.

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• Like in other PowerFlex drives the parameters have been grouped in a comprehensive manner
• These groups can be seen from the HIM display, on the Connected Components Workbench and in Studio 5000

• Dedicated application parameter groups have been created to help our customers with the startup of their particular
application
• 8 AppView groups have been created containing the most common parameters for these applications

• Customers can also create their own parameter groups by creating a custom View. You can start from scratch or
use one of the AppView groups as a base.
Specific firmware features have been added to increase the drives versatility:

• Point stop: Provides a method to stop at a constant distance instead of a fixed rate (without encoder).

• Positioning capability (with encoder) using the StepLogic engine.

• Motor heating can be activated via digital input (or network). The drive will force a small amount DC current into the
motor against condensation.

• Sleep/Wake: The drive can start and stop itself based on the level of an analogue input (programmable threshold
levels)

• Load loss detection: The drive can detect a certain drop in load and fault according to programmed level

• The drive contains two PID loops and two shear pin detections.

• Different parameter protection levels can be achieved.

• Output phase loss detection: A three-phase motor running on two phases only will not develop a lot of torque. This
detection will fault the drive if one phase is missing.

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• Serious effort has gone into providing good language support. The list is shown above.

• The scrolling text is a nice feature. Instead of showing parameters just with P041 ..the display will start scrolling the
parameter description after a while. The same will occur for fault message. F04......undervoltage.

Energy-Centric Features
  Economizer SVC
 Automatic reduction of output voltage at constant load
 Reduced output power
 Full output voltage resumed at load or speed change

 Permanent magnet motor control

 Higher motor efficiency and smaller frame size  Gearless
systems

 Energy savings tracking parameters

 Monitoring of energy usage to assess energy consumption

 CIP Energy reporting

 EtherNet/IP supported function
 Data object contains P, $, and CO2
Copyright ©2013 Rockwell Automation, Inc. All rights reserved.10

Energy savings are critical topic these days. A number of things have been added to make sure the drive is ready
to follow this trend:

• Economiser SVC: A control method that will automatically lower output voltage to the motor when it’s running with
constant speed at constant load and thus saving energy.

• In a second release, the drive will support permanent magnet motors. Those motor tend to have better efficiency
values than standard induction motors. Again, the feature is not supported at time of release.

• The drive contains several parameters that allow the operators to monitor energy usage.

• The drive’s firmware also contains the CIP Energy object. It comprises a set of internal objects that keep track of a
number of well defined (ODVA driven) energy related parameters. The object can be read by automation controllers
and will allow for easy energy reporting and management.

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• PowerFlex 525 are very versatile and can be applied to a wide range of applications. You are probably familiar with
most of those listed above.

• Be aware of the following application restrictions:

• Drive power is limited to 22 kW
• No absolute encoder support
• No genuine torque control

You have completed the introductory presentation.

Please move on the hands-on labs.
About This Hands-On Lab

About This Hands-On

Get familiar with new PowerFlex 525 compact AC drive; the next generation compact drive. Experience
certain key features (like AppView™ a new feature that provides specific parameter groups for popular
applications) whilst learning the basics of drive programming.
Attendees will configure these drives using the Human Interface Module (HIM), Connected Components
Workbench™ and Studio 5000 (formerly RSLogix 5000). You will also try AppView™. Finally, experience the
drive’s ease of integration into the Logix environment using the embedded Ethernet port and add-on profiles
in Studio 5000™.

Lab Materials

For this Hands-On lab, we have provided you with the following materials that will allow you to complete the labs in this
workbook.

Ethernet Connections

1 PC L18ERM Port 1 (front)

2 L18ERM Port 2 (rear) ETAP Port 1 (front)
3 ETAP Port 2 (rear) PF525

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Software
• Studio 5000™ v28

• Connected Components Workbench™

• RSLinx Classic™
• FactoryTalk View Studio
• RSLinx Enterprise

Hardware
• PowerFlex 525 Demo Box (12P019A)

• 1769-L18ERM-BB1B v21

• PowerFlex 525 v1.002 (beta)

• Ethernet patch cables

• USB cable

Files required
 PF_525_USB_setup.pf5
 PowerFlex_525_Lab_start.ACD
Files are located in Lad and Demo On Desk top\CoTMD07- PowerFlex 525 intro A shortcut has
been placed on the desktop.

Document Conventions

Throughout this workbook, we have used the following conventions to help guide you through the lab materials.
This style or symbol: Indicates:
Words shown in bold (e.g., IO Any item or button that you must :
Configuration or OK) - Click on, or a menu name from which you must choose an
option or command. This will be an actual name of an item
that you see on your screen or in an example.
- Type in the specified field. This is information that you must
supply based on your application (e.g., a variable).

The text that appears inside of this gray box is supplemental information regarding the lab materials, but not
information that is required reading in order for you to complete the lab exercises. The text that follows this symbol
may provide you with helpful hints that can make it easier for you to use this product. Most often, authors use this
“Tip Text” style for important information they want their students to see. Note: If the mouse button is not specified in
the text, you should click on the left mouse button.

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Lab#1: Drive Overview

About This Lab

Under the hood
In this section you will identify the different components under the cover of the PowerFlex 525.

Locate the Drive Power switch and make sure it is set to OFF. The drive display should be off.
Open the drive cover by pressing and holding down the arrow (1) and sliding the front cover down (2), as shown in the
picture below.

Take a few moments to identify the different components inside the drive, the picture below highlights the major ones.
Lab#2: USB Functionality

About This Lab Behind the control module

In this section you will learn how to use the USB programming functionality of the PowerFlex 525.

The following steps will guide you how to remove separate the control module from the power module.
This will typically be done before any IO wiring so please be careful while executing the procedure on this demo case. 1.
Press down and slide out the top cover of the Control Module to unlock it from the Power module

2. Hold the sides and top of the Control Module firmly, then pull out to separate it from the Power Module
You can now see the back of the control module albeit upside down due to the attached wiring (shown on the left).This
is also where you would mount the optional communication cards (shown on the right hand side - not part of the lab)

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USB Functionality

The PowerFlex 525 drive has a USB port that connects to a PC for the purpose of upgrading drive firmware or
uploading/downloading a parameter configuration.
You do not need to power up the control module. Simply connect the PowerFlex 525 drive to your PC with a USB Type B
cable, and you will benefit from MainsFree™ programming.

This USB cable is the same cable used for printers these days. The cable provided with the 1203-USB
converter can also be used

1. Locate the USB cable that is provided. Connect it to the drive and to the USB port of the PC.

2. Wait until you see the window shown on the left hand side. Open the folder, this will show the two files stored within
the drive.

3. Double-click on GUIDE.PDF. This opens a small reference document, stored in the drive, with a parameter listing
and fault descriptions. (We all know how easy it is to misplace user manuals)
Close the document.
4. Double-click on PF52XUSB.EXE. This opens the software utility that allows you to upload or download parameter
or to upgrade the drive’s firmware. Click on download.
5. Locate the file to download PF525_USB_setup.pf5. It is stored in the Lab and Demo library, under
CoTMD07PowerFlex 525 intro. Click on PF525_USB_setup.pf5 and click Next.

6. Click on download and ok in the two following windows. This completes the download of a stored (preconfigured)
parameter file. Close the download windows and the USB application window.

This USB application is an easy way to configure the PowerFlex drive without the need of dedicated software package. One example
could be panel builders having their electricians mount and wire the drives’ power modules while the software engineers
preconfigure the drives’ control.
7. Remove the USB cable from the drive. Replace the control module.
Align the connectors on the Power Module and Control Module then push the Control Module firmly onto the Power
Module.

8. Push the top cover of the control module towards the power module to lock it. Refit the front cover of the drive.

9. Once the control module is back in place you can power up the drive by turning the switch to on.
Make sure the controller L18ERM 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).

10. The preconfigured parameter file programs the drive in 3 wire start/stop control with the drive’s potentiometer as
speed reference. (Red button = stop, Start switch= start, Dir switch = change direction, DI1 = select Preset
Frequency 1). Test the functionality.

Congratulations! You have completed the Lab.

 Please move on to Lab 3.

Lab#3: Using the HIM Keypad & Display

About This Lab

In this section you will perform the following with the Keypad:

 Review key information about the HIM keypad and display of the PowerFlex 525
 Configure some parameters

Review the following information carefully. As it explains how to modify parameters via the HIM keypad which is needed
throughout this lab

HIM Keypad & Display

The PowerFlex 525 is easy to configure with flexibility in programming options to meet your application. One of which is
the Liquid Crystal Display (LCD) Human Interface Module (HIM). Some of its key features are as follows:

• Improved visibility
• Increased resolution
• Descriptive scrolling text o Three adjustable speeds

• Full Alphanumeric with 5 Digits and 16 Segments

• Supports multiple languages o

• English o French o Spanish o Italian o German o

Portuguese o

Polish o

Turkish o

Czech

Display and Control Keys

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  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 a max of 100 parameters
 Save new “CustomView” for easy copy and paste

The AppView and CustomView will be explained in details at a later stage.

Control and Navigation Keys

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.

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Configure parameters
Add some functionality to the parameter file previously downloaded. If this was a conveyor system you may want to add
the Shear Pin detection, this is pretty common for conveyor installations.
A shear pin is some sort of mechanical safety device designed to shear in the case of a mechanical overload, preventing
other, more-expensive parts from being damaged. It works as a mechanical sacrificial part, it is analogous to an electric
fuse.
This same functionality can be programmed in the drive, the shear pin becomes an electrical detection.

1. Find the Shear Pin 1 Level parameter A486 (Advanced program group). Modify this parameter to 0.2A.

or
The drive will immediately fault when it hits the 0.2A output current level. Press until the group letter starts

flashing, used Up or Down arrows to change to the A group. Press the Enter or

Sel button to enter the Advanced program group. The right digit of the last viewed parameter in that group
will flash. Enter 486 with the Up or Down arrows (to change the value) and the Sel button to

switch between digits. Press to be able to change the value.

2. Change the display parameter to show the output current b03. Press until the group letter starts flashing,

used Up or Down or arrows to change to the b-group. Press the Enter or Sel

button to enter the basic display group. The

right digit of the last viewed parameter in that group will
flash. Enter 03 and validate. The HIM is now programmed to show the output current.

3. Turn the potentiometer all the way to the right demanding 50Hz speed reference. Verify the DI1 switch is turned to
the left.

4. Monitor the display and start the drive. It will accelerate to the maximum speed reference. Use the DIR switch to
change direction quickly (do this a couple of time to simulate forward / reverse operation). What happens?

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5. The drive faulted with F063 with a scrolling message “SW Overcurrent”, this immediately gives you the fault
description without the need to refer to the user manual. The scrolling speed is parameter adjustable.

6. To clear the fault Press the Stop button on the drive keypad or on the demo case.

Once the fault is cleared you can display the last fault codes by navigating to parameter b07 [Fault code 1] =
the most recent fault, b08 [Fault code 2] and b09 [Fault code 3]. The fault and diagnostic group contains
more fault information regarding the last 10 faults (F604  670). The drive stores output current, output
frequency, bus volts and drives status at the time of the fault.
The drive software can also be used to display the fault queue. (Explained at a later stage)

7. To make sure this Shear Pin fault does not occur during accelerations you have the possibility to program a Shear
Pin time. This sets the continuous time the output current must at or above current level programmed in Shear Pin
level. You can program this parameter using the keypad or using the drive programming software. This will be
covered in the next lab.

Congratulations! You have completed the Lab.

Please move on to Lab 4.
Lab#4: Utilizing Ethernet/IP and Connected Component
Workbench™
About This Lab

Currently, Connected Components Workbench™ programming and configuration software supports the
Micro800™ controllers, as well as the PowerFlex® 4 & 7-class drives and PanelView™ Component graphic
terminals, for your small machine applications.

A future release of Connected Components Workbench™, version 3, will support the PowerFlex 525 drive.
Besides Studio 5000 it will be the only software package that fully supports the PowerFlex 525. For this lab,
you will be using a beta version of the Connected Components Workbench™ software.

In this section you will perform the following:

• Connect to the PowerFlex 525 through the embedded Ethernet/IP via Connected Components
Workbench™

• Locate the fault queue

• Search and modify parameters

• Explore the different parameter groupings as well as the AppView™.

• Create a CustomView™
• Explore the Startup wizard.
Connecting to the Drive with Connected Component Workbench

1 . Double click the Connected Components Workbench™ shortcut.

You will see the following splash screen while the software loads.
2. The main screen for Connected Components Workbench™ is as follows.

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Note: You may want to maximize the Connected Components Workbench™ software to make viewing easier.

3. Although there are many features with Connected Components Workbench™, we will just be using the
software to go online with the PowerFlex 525. Click the [+] next to the Discover within the Device Toolbox.

4. Click the Browse Connections button to launch the RSWho connection browser.

5. The lab’s preconfigured RSLinx driver. Click on the [+] to expand AB_ETHIP-1, Ethernet, Click/Highlight
the 192.168.1.20 (preconfigured address), 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 within the Connected Components Workbench™ software.

7. Click on the in the menu bar. This will open the fault queue. Notice the SW overcurrent fault F063
triggered by the shear Pin detection.
Fault queue

8. Press the Clear Fault queue button. This will clear the list. Close the fault queue window.

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Search and Modify Drive Parameters

It is easy to navigate to a parameter if you know its number. Unfortunately this is not always the case. There must a
way to find parameters in a different manner.

9. Click on icon to open the following view. the Parameters

 10. The Filter Value field can be used to narrow down the list. Type in the first letters of Shear. Notice how the
list changes with each letter you enter. Modify P487 Shear Pin 1 Time to 1s. Make sure you press enter
(PC keyboard) to validate the setting.

12. Try some other filter values like dig or speed.

Remove the filter value as it will restrict the parameter view no matter which group you are in.

Exploring Drive Parameters via Parameter Groupings, AppView™ and

CustomView™

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

14. Take some time to explore them. Please keep in mind that some features are not implemented yet due to
this drive and software still in its beta stage.

1.00

You could also filter by entering the value 48 if you remembered the parameter was somewhere in the 48x range.
It will filter out all parameter containing the numbers 48. ( 481,482,…but also 48)

11. Start the drive and change direction a couple of times. Does the drive still fault?

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

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

18. An upload progress window will pop up.

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19. Once the upload has completed you will see the parameters window update to just show only the nondefault
parameters. Take a look at the list you will for example notice that the Shear Pin 1 Time parameter has
been changed.
The print icon on top right corner of the window allows you to print the list with changed parameters. This is a
sheet that we sometimes find in the electrical panels.

20. Click the Show All button to return to viewing all of the PowerFlex 525 drive parameters.
 21. Under the Group: dropdown selection box, you can scroll through the different drive parameter groups,
AppView™ and the CustomView™.

22. Click on Basic Program and explore the parameters.

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/commission parameters.

23. The PowerFlex 525 drive has several AppView™ groupings that are tailored for a specific application to
make the respective drive startup/commission simpler. No more guessing what parameters you need to
change, drive parameters for that application are all in one convenient location. The AppView™ groups are
locked down in the drive firmware.

For example, within the Group dropdown selection box, click on the Conveyor AppView™. Scroll through
these application specific parameters, some are shown below.
 24. How can these AppView™ groups be accessed through the HIM keypad? Locate the G-group parameters.
There are 8 AppView™ groups (G1= conveyor, G2= Mixer …). Enter the G1-conveyor group and navigate
through the parameters. Notice how the parameters only scroll through this particular list.

You can easily imagine that, in an AppView™ group, some people may be missing a couple of other parameters
needed for their particular machine. In this case we can resort to the CustomView™. This is an application set that
can be customized specifically for your application. You can add up to a maximum of 100 parameters and save the
new “Custom View”.

25. Select Custom Group (1) from the Parameter Group dropdown selection box. Notice how the list is empty.
Click on the Edit Group (2) button.

1 2

26. The Edit Custom Group window will appear. Here you will be able to select and add parameters into a
nameable custom group.
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27. Open the tree structure on the left hand side Click on the Conveyor group. Imagine you are working with
conveyors but you are missing the Shear Pin parameters in the Conveyor group. Select all the Conveyor
group parameters (Use common Windows controls like CTRL+A or Shift+mouse click to highlight all these
parameters). Click the Add button to load the parameters in the custom group.

You can also double click on a parameter to add it to the custom list rather than clicking Add.

28. Once the base parameters have been added you can now add the Shear Pin 1 level and Shear pin 1 Time.
Locate and add P486 and P487. Modify the name to Cust_X_conveyor or create your own custom group
name. Click OK to validate.
 29. Notice how the parameters entries from above are all now in the Cust_X_conveyor Group CustomView™ for
easy parameter viewing and editing.

Copying the parameters from an AppView™ to the Custom View group is also possible using the HIM
keypad. The procedure is explained in the PowerFlex 525 user manual

Protecting Parameters

In some cases it’s important to lock down parameters to prevent accidental changes that could seriously affect
machine operation. The drive allows different methods of protection.
The method is selected by parameter A553 Program Lock Mod, the password (4 digits) can be entered in parameter
A552 Program lock. Once the drive has been locked P552 Program lock will show a value of 1 (not locked = 0).
Program Lock Modes
• Full lock: All parameters are locked except A552 Program lock
• Keypad lock : All parameters are locked except A552 Program lock from keypad access but can still be
accessed over communications
• Custom only: All parameters are locked and hidden except custom group and A552 Program lock
• Keypad Custom: All parameters are locked and hidden except custom group and A552 Program lock from
keypad access but can still be accessed over communications
30. Make sure A553 Program lock Mod is set to Full lock. Enter 50 as password in A552 Program lock.
Check that A552 value changes to 1.

31. Browse through the parameters groups using the keypad, all parameters should be visible. Use the
keypad to change P041 accel time 1 to 5s. Does the drive accept this value? Try to change the same
parameter using the software. You should get the following error message.
Place Controller in PROG Mode
 • 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”. This selection can be used when swapping control modules between differently
rated power modules.

4. Click the Reset button for the second option, Reset all settings to factory defaults (including the custom parameter
group)

Click Yes and once you see, , Click the Next > button to proceed to the next page.

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

6. Make sure English is selected in the Language dropdown selection box.

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7. Click the button to proceed to the next page. Next

> Go through, verify and if needed, modify the parameters according to the following screenshots.
8.
button to proceed to the next page
Remember to Click the Next >
9. Perform the direction test. Enter a speed reference of 5Hz. Click yes when the speed reference message appears. Click
the green start button on the screen execute the test. The drive will ramp up motor speed up to 5Hz and lets you
evaluate the forward direction of the application. Tick the box next to yes, the green checkmark will appear.

10. Execute a rotate tune. The rotate tune consists of static part (to measure voltage drops) and a dynamic part to measure
the flux current. This is the recommended tuning when in a vector control regulation method. The static tune should be
used if the motor can’t be uncoupled from the load. When completed the green checkmark will appear.
CoTMD07 - Introduction to PowerFlex 525 Compact AC Drives
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11. Select Speed reference 3 tab and change speed reference 3 to keypad Freq. This is required as the wizard
programmed speed reference 1 to the Ethernet reference when the direction test was executed.
 Keep all other steps at Default

12. Once changes have been made, Go to the Pending Changes page for a summary of the
planned programming changes you have made to the PowerFlex 525 drive.
 Make sure all the Pages have the black check

button to accept pending changes.

Click the Finish >>

13. The main PowerFlex 525 window will be present. Click the Reset button for the Ethernet communication settings
to take effect.

14. Click OK. You will hear the PowerFlex 525 cycle power and the HIM Keypad display turn off and on and start scrolling the
drive power ratings

15. This is a pretty quick process. You will see the following screen.
16. Click OK. You will screen the main PowerFlex 525 screen go from this…

to this
once…the Connected Components Workbench™ software has re-established it’s connection with the drive.

17. Click on the Control Bar icon to test the Ethernet functionality. Click ok when the following message appears.

18. Set the speed reference by dragging the bar to the right. Set to 40Hz or so. Start the drive using the green start button.
The blue arrow reflects the direction the motor is turning, use the fwd/rev button to verify. Stop the drive. Close the
control bar by clicking the control bar icon.

19. Exit Connected Components Workbench™ software.

20. When prompted, click No.

CoTMD07 - Introduction to PowerFlex 525 Compact AC Drives

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21. When prompted, click No.

Congratulations! You have completed the Lab. Please move on to Lab