L14 - Drive Programming with the New PowerFlex® 520
L14 - Drive Programming with the New
PowerFlex® 520-Series AC Drive
For Classroom Use Only!
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•
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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
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• 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.
Drive Programming with the New PowerFlex 520-Series AC Drive
Contents
Before You Begin .......................................................................................................................................... 5
About this lab .................................................................................................................................................................................... 5
Tools & Prerequisites ........................................................................................................................................................................ 5
Network Setup ............................................................................................................................................... 6
About the Demo Box ..................................................................................................................................... 7
Exercise 1: Using the HIM Keypad and Display ........................................................................................... 8
Information ........................................................................................................................................................................................ 8
Reset Drive to Defaults ................................................................................................................................................................... 12
Configuring Drive Parameters......................................................................................................................................................... 14
Exercise 2: Utilizing EtherNet/IP™ and Connected Components Workbench™ Software ........................ 15
Connecting to the Drive .................................................................................................................................................................. 15
Exploring Drive Parameters through Standard Parameter Groupings ............................................................................................ 18
Exploring Drive Parameters with AppView™ and CustomView™ Groupings ................................................................................ 22
PowerFlex 525 Drive Start-Up Wizard ............................................................................................................................................ 24
Exercise 3: PowerFlex 525 Drive Add-On Profile with Drives and Motion Accelerator Toolkit. ................. 34
About Integrated Drive Profiles and Premier Integration ................................................................................................................ 34
Exploring the Add-On Profile for the PowerFlex 525 Drive ............................................................................................................. 35
Taking Advantage of Having the Drive in the Controller Organizer ................................................................................................ 42
Downloading the Project ................................................................................................................................................................. 45
About Drives and Motion Accelerator Toolkit (DMAT) .................................................................................................................... 51
Switch to the HMI Application ......................................................................................................................................................... 51
Faceplate Operation ....................................................................................................................................................................... 52
Bonus Lab Exercise: Automatic Device Configuration (ADC) with the PowerFlex 525 AC drive ............... 61
About Automatic Device Configuration (ADC) ................................................................................................................................ 61
Exploring the Setup of Automatic Device Configuration (ADC) ...................................................................................................... 62
Demonstrating Automatic Device Configuration ............................................................................................................................. 66
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Reset the System............................................................................................................................................................................ 68
Appendix: Overview of the DMAT ............................................................................................................... 69
Machine/Application/Device Module Relationship .......................................................................................................................... 70
Module Routine Overview ............................................................................................................................................................... 71
Machine Module.............................................................................................................................................................................. 72
Machine States ............................................................................................................................................................................... 72
Machine State Diagram .................................................................................................................................................................. 73
Default Machine States ................................................................................................................................................................... 74
Default Machine Commands ........................................................................................................................................................... 74
Machine Control Module Tags ........................................................................................................................................................ 75
Machine Tags ................................................................................................................................................................................. 75
Device and Application Status Rungs and Logix ............................................................................................................................ 75
Application Modules ........................................................................................................................................................................ 79
Device Module Control Logic .......................................................................................................................................................... 83
Notes ........................................................................................................................................................... 84
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Before You Begin
Please review the following information before starting this lab.
About this lab
Learn the basics of drive programming using the new PowerFlex 525 compact 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 new feature that provides specific parameter groups for popular applications. 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 525 drives in Studio 5000.
Tools & Prerequisites
Software programs required
 Studio 5000 Logix Designer v23.00.00

PowerFlex 525 Add-On Profile v1.04.33

Connected Components Workbench v6.01.00

RSLinx Classic v3.61.00

FactoryTalk View Studio v7.00

RSLinx Enterprise v5.60.08

Wizards v3.12.11
Hardware devices required
 PowerFlex 525 Demo Box (12P019A)

o
CompactLogix 5370 Controller (1769-L18ERM-BB1B) - v23.012
o
PowerFlex 525 AC Drive (25B-V2P5N104) – v2.003
Ethernet patch cables
Files required

PF525_Lab.ACD

PF525_Lab_ADC.ACD

PF525_Lab.mer
Lab files are located within the “C:\Lab Files\L14 – Basic Drive Programming” folder.
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Network Setup
Ethernet Connections
1
2
3
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PC
L18ERM Port 1 (front)
L18ERM Port 2 (rear)
ETAP Port 1 (front)
ETAP Port 2 (rear)
PF525
About the Demo Box
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Exercise 1: Using the HIM Keypad and Display
In this section you will perform the following:
 Review key information about the HIM keypad and display of the PowerFlex 525 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
4. Press the Esc
button to clear the fault from the drive.
button until you see zero speed on the keypad display.
5. Press the Select
button and use the Up
Program group on the HIM display.
6. Press the Enter or Sel button
parameter in that group will flash.
or Down
arrows until you see the Basic
to enter the Basic Program group. The right digit of the last viewed
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
The digit or bit that you can change will flash.
8. Once P053 is displayed, Press the Enter
display. Press the Up
or Down
button to move from digit to digit or bit to bit.
button. You will see “0 - Ready/Idle” scroll across the
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 Drive Parameters
1. Take what you have learned about the keypad operation from the Reset Drive to Defaults section to make
the following Communication group parameter changes:

C128 – EN Addr Sel = 1 - “Parameters”

C129 – EN IP Addr Cfg 1 = 192

C130 – EN IP Addr Cfg 2 = 168

C131 – EN IP Addr Cfg 3 = 1

C132 – EN IP Addr Cfg 4 = 20

C133 – EN Subnet Cfg 1 = 255

C134 – EN Subnet Cfg 2 = 255

C135 – EN Subnet Cfg 3 = 255
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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Exercise 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. 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. Take a look, you will notice that the parameters you changed in Lab 1 appear in this
list.
5. Click the “Show All”
button to return to viewing all of the PowerFlex 525 drive parameters.
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6.
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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7. Under the Group dropdown selection box, you can scroll through the different drive parameter groups,
AppView groups and the CustomView group.
8. 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.
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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.
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 – PowerFlex 525_1* window by clicking the [X] 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 >”
next page.

Motor Control Page

Motor Data Page (changes required)

Feedback Page

Stop / Brake Mode Page
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button to proceed to the
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)


Relay Outputs (changes required)
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
Opto Outputs

Analog Outputs
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.
13. The reset happens quickly. You may see the following screen appear If it does, click the “OK” button.
While the computer is reconnecting to the drive, your screen may show the following graphic for a moment.
After the connection has been established with the drive again, the window will return to its normal state.
14. Exit the Connected Components Workbench software. You may be prompted to upload parameters from
the drive or to save the project. Select the “No” button for each.
Continue on to the next exercise.
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Exercise 3: PowerFlex 525 Drive Add-On Profile with Drives and Motion Accelerator Toolkit.
This section will provide a preview of the PowerFlex 525 Drive Add-On Profile as well as the Drives and Motion Accelerator
Toolkit Add-On Instructions and Faceplates for the PowerFlex 525 drive.
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.
3. Select the “PF525_Lab.ACD” file and click the “Open” button.
Lab files are located within the “C:\Lab Files\L14 – Drive Basic Programming” folder.
The file will be opened in the Logix Designer software after a few moments.
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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-EENET
PF525_Drive”.
The Module Properties window will appear.
5. Click on the tab labeled “Drive”.
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.
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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
= Reset device data to factory defaults
= Print
If you forget each button’s purpose, hold your cursor over them and they will display a tooltip with their
function.
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7. Click on the “Communications” 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. 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 file format is not compatible with DriveExplorer or DriveExecutive, and 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. 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
11. 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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12. 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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13. 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 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.
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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!
4. In addition to storing the configuration data in the controller, the controller manages the communications to
the drive with convenient tag-based addressing. Double-click on the “Controller Tags” icon under the
“Controller PF525_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 PF525_Lab project. Click the “Open” icon illustrated below.
2. Select the “PF525_Lab.ACD” file and click the “Open” button.
3.
Open the drive Module Properties window by double-clicking on the “PowerFlex 525-EENET
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 select the “192.168.1.20, PowerFlex 525” node.
Click the “OK” button
7.
You will be asked to confirm with the window shown below. Click the button to “Download Entire Device”.
8.
For a brief moment, you will see a downloading progress bar while the parameter settings are being sent to the drive.
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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 close the Module Properties window,
12. Click on “Communcations” in the menu bar and select “Who Active”.
The Who Active window will appear.
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13. 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.
14. When the confirmation window appears, click the “Download” button again.
You will see a progress bar
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15. Put the controller in “Run” mode. One way to do this is by clicking on the mode drop-down arrow and select
“Run Mode”.
16. When prompted to confirm switching the controller mode to “Remote Run”, click the “Yes” button.
17. Verify that the “DI1” selector switch is in the left-hand position.
Continue to the next section of the lab.
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About Drives and Motion Accelerator Toolkit (DMAT)
Publication IASIMP-QS019 is a quick start guide that provides step by step instructions for using the Drives and Motion
Accelerator Toolkit to help you design, install, operate, and maintain a drive system. Included are selection tools, layout and
wiring drawings, and pre-configured logic and HMI files to assist you in creating an Integrated Architecture solution for your
application requirements.
All the supporting files are included on the Drives and Motion Accelerator Toolkit (DMAT) DVD, publication IASIMP-SP017. The
DVD provides drive selection tools; CAD drawings for panel layout and wiring; basic status, control, and diagnostic logic files;
FactoryTalk View ME and SE faceplates, and more. With these tools and the built-in best-practices design, the system designer
is free to focus on the design of their machine control and not on design overhead tasks. You can also download these same
supporting files from the Rockwell Automation Integrated Architecture Tools website, http://www.ab.com/go/iatools on the
Beyond Getting Started tab.
In this section, the FactoryTalk View project has already been made. You will explore the runtime application.
Switch to the HMI Application
1. Minimize Studio 5000 Logix Designer so that the HMI screen on the desktop can be seen.
2. If the warning screen is displayed, click the blue “OK” button to load the Startup screen.
3. The Startup screen should now be displayed, though some of the indicators will be in a different state.
The Startup screen provides machine status and control, plus it allows navigation to all other screens. Take a moment to
familiarize yourself with the Startup screen before moving on to the next section.
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Faceplate Operation
The Startup screen display provides machine control as well as the main navigation screen to launch all other faceplates or
screens that provide additional equipment control, status, and alarm history. This display can be configured to suit your machine
or system needs.
Machine Control
Program (AUTOMATIC) mode refers to the automatic function or automatic sequencing for the machine. Operator (MANUAL)
mode allows for some manual operations, like start, stop, forward, reverse, jog, etc. The machine status indicators provide a
summation view of all the devices for the entire machine. The “Program/Operator” selector button lets you toggle between the
two modes.
The “Clear Faults” button attempts to clear faults on all devices. The condition that caused the fault must be corrected before the
clear is successful.
The State Diagram faceplate can be accessed by pressing the “State Diagram” button. While in Program mode, the state
diagram illustrates the machine operational model:
The states with a dashed outline indicate a transitional state; while the solid line indicates an end state.
Depending on your current machine state, use the following commands to transition between states:
ABORTED – Press Clear Faults
ABORTED  CLEARING  STOPPED
STOPPED – Press Start
STOPPED  RESETTING  IDLE  STARTNG  RUNNING
RUNNING – Press Stop
RUNNING  STOPPING  STOPPED
The machine is placed into the ABORTED state whenever a drive fault condition and/or a state transition
error has been detected. The machine is also placed into the ABORTED state on Power Up or during “first
scan” (i.e. Program to Run Mode) of the controller. Refer to the Alarm History faceplate to determine the
cause for the ABORTED condition.
If you opened the State Diagram faceplate, close it by pressing the [X] in the top-right corner.
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Run the Machine
Follow these steps to start and stop the system while in Program mode.
1. If the machine is currently in the ABORTED state, press the “Clear Faults” button.
After a few moments the state machine should transition to the STOPPED state.
2. Press the “Program/Operator” button until “Program” is displayed. Program mode (AUTO) is now the
active control mode.
3. Press the “Start” button. The system begins operating according to the Studio 5000 Logix Designer
program.
The description from the ladder logic program is shown here.
4. Let the system run for about one minute to see the full cycle of the ladder logic. Once satisfied, press the
“Stop” button.
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5. After the system stops, press the “Program/Operator” button until it displays “Operator”.
The machine must be stopped before you can switch control modes. When in Operator (MANUAL) mode,
you can individually control each axis from its corresponding faceplate.
Continue to the next section.
Using the PowerFlex 525 Drive Faceplate
1. Press the “PF525” button from the Startup screen.
The faceplate will appear.
The PowerFlex 525 faceplate provides status information, fault information, and trending data. The faceplate also includes
the ability to manually control the drive.
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2. Click on the outlined numeric entry to display keypad to change the speed reference of the drive.
The numeric box performs a dual purpose. It displays the drive feedback, but can also be used to enter
information. After you click the “Enter” button the value is stored but not displayed. Once the motor is
spinning, the value will be updated.
3. Type a value between 0 Hz and 60 Hz and press the “Enter” ( ) button on the keypad to confirm.
The faceplate will technically allow a higher value to be entered, but the drive will limit to 60 Hz in any case.
4. Click the “Start” button in the PF525 faceplate.
The drive will start turning the motor at the commanded speed. You can see the speed feedback changing in the numeric
box on the faceplate.
5. After making the motor come to reference speed, click the “Stop” button in the PF525 faceplate.
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6. Press the “Faults” button.
The Faults faceplate will come up. It may look different than the screenshot below, since it will display the last fault.
If a fault condition exists, the Faults icon flashes red. This faceplate determines the fault information from the drive and
displays the fault type, code and description. When there is no active fault, the display shows the last fault condition
recorded.
7. On the demo box, push in the red “Safe Off” button to generate a fault on the drive. This will generate a
F059 – Safety Open fault.
8. Press the “Help” button for more information about the fault.
The Help screen displays the fault descriptions and actions.
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9. Press the arrows to switch between screens.
You can clear faults from the Startup screen or, if in Operator mode, from the Fault display. The Alarm History screen logs
fault information from all of the devices.
10. When you are finished, pull out the red “Safe Off” button and press the “Clear Faults” button on the
Startup screen to clear the fault in the drive and the state machine.
11. Press the “Configuration” button.
From the Configuration screen you can enter display names and units as required for your application.
Some of the labels are used on the Equipment Status faceplate.
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12. Press the “Trend” button.
The Trend screen lets you view Speed Feedback and any other pens are setup up.
13. Press the “Trend Configuration” button.
The Trend Configuration button is only visible from the Trend screen.
The Trend Configuration screen lets you adjust the trend scales.
14. When you have finished exploring the PowerFlex 525 drive faceplate, close it by pressing the [X] in the top
right corner of the faceplate.
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The Alarm History Faceplate
The Alarm History faceplate provides a summary of current and past alarms for all of the configured devices or drives configured
in the application. The faceplate receives fault information directly from each of the device modules and applies a timestamp
based on the order in which it was received.
1. Press the “Alarm History” button on the Startup screen to open the faceplate.
The Alarm History faceplate can be an effective diagnostic tool for troubleshooting, helping machine operators pinpoint root
cause for problems quickly.
2. When you are done with the Alarm History faceplate, close it by pressing the Close button on the bottom of
the screen.
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The Equipment Status Faceplate
The Equipment Status faceplate lets you quickly load and configure a summary display of preconfigured status and diagnostic
displays (faceplates). The Equipment Status faceplate works in conjunction with individual device faceplates and provides a
single summary display of all the devices that may be configured for an application.
1. Press the “Equipment Status” button on the Startup screen to open the faceplate.
You can configure up to nine device faceplates to run with the Equipment Status screen and each device faceplate can be
launched directly from it by clicking on the device name.
2. When you are done with the Equipment Status faceplate, close it by pressing the [X] in the top-right corner.
3. Switch back to Studio 5000 software. From the “File” menu, select “Close” to exit the current project.
4. If you are prompted to save the changes to the program, click the “No” button.
If time permits, continue to the next lab section.
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Bonus Lab Exercise: Automatic Device Configuration (ADC) with the PowerFlex 525 AC drive
About Automatic Device Configuration (ADC)
Automatic Device Configuration (ADC) is a feature (in Version 20 of RSLogix 5000 software and Version 21 or higher in Logix
Designer software) that supports the automatic download of configuration data whenever the Logix controller establishes an
EtherNet/IP network connection to a PowerFlex 525 drive and its associated peripherals.
ADC is available when the PowerFlex 525 drive is connected using the embedded EtherNet/IP adapter or
EtherNet/IP DLR adapter to a compatible controller. ADC is available when the PowerFlex 523 is connected
using the EtherNet/IP DLR adapter to a compatible controller.
The project file and controller contain the configuration settings for any PowerFlex drives in the project. When the project is
downloaded to the controller, these settings are also transferred and reside in the controller’s memory. ADC automates the
process of downloading the configuration to the drive and saves you time. It is particularly beneficial in a drive replacement
situation where maintenance personal may not have access to laptops or workstations.
This feature is currently available for the following PowerFlex drives:
 PowerFlex 525 via Embedded Ethernet (EENET) and Dual Port Ethernet (E2P)
 PowerFlex 523 via Dual Port Ethernet (E2P)
 PowerFlex 755 (Version 4.001 and up) via Embedded Ethernet (EENET) and Dual Port Ethernet (ENETR)
 PowerFlex 753 (version 7.001 and up) via Dual Port Ethernet (ENETR)
ADC can also work in tandem with Firmware Supervisor. When Firmware Supervisor is set up and enabled in the project, and if
the respective ControlFLASH firmware kit is installed on the computer when the project is downloaded, the drive and peripherals
will be automatically brought to appropriate firmware revision if needed. This further reduces the need for maintenance personal
to access laptops and workstations while replacing drives.
The controller project owns the configuration of the drive. ADC will be triggered any time the controller
detects a configuration signature mismatch when establishing an EtherNet/IP network I/O connection.
The use of other configuration tools, such as a HIM or Connected Components Workbench software should
be minimized and restricted to monitor-only operation. Any configuration changes made by these tools will
cause a configuration signature mismatch the next time the Logix controller connects to the device and ADC
will write over any changes made by the other tool(s). Any drive configuration changes should be made with
the drive Add-On Profile.
This exercise will help teach you how to set up ADC for a drive. For more information in regards to the PowerFlex 525 drive and
Automatic Device Configuration (ADC), refer to the PowerFlex 525 Embedded EtherNet/IP Adapter User Manual. There is also
information about Automatic Device Configuration (ADC) in the PowerFlex 25-COMM-E2P Dual-Port EtherNet/IP Adapter User
Manual.
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Exploring the Setup of Automatic Device Configuration (ADC)
1. From the “File” menu, select “Open…” to select an existing project.
2. Select the “PF525_Lab.ACD” file and click the “Open” button.
Lab files are located within the “C:\Lab Files\L14 – Basic Drive Programming” folder.
3. 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-EENET
PF525_Drive”.
The Module Properties window will appear.
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4. Click on the tab labeled “Drive”.
The Drive tab will appear. The drive AOP requires deliberate action to enable ADC. This helps ensure that ADC is fully
understood prior to turning it on.
The drive AOP also has an ADC icon on the Drive tab that shows if ADC is enabled (green arrow) or disabled (gray arrow)
for that drive.
5. Click on the “ADC” button.
This will open the Automatic Device Configuration setup window.
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6. The picture below shows how to enable or disable ADC for the PowerFlex 525 drive and its peripherals (if
applicable). Click the check box that his highlighted below to enable ADC.
7. Click the “Apply” button in the Automatic Device Configuration window and close the window.
In order for setting changes to take effect, you must click the “Apply” button before closing the window with
the [X] at the top corner.
8. Click the “OK” button to close the Module Properties window.
9. Click on “Communcations” in the menu bar and select “Who Active”.
The Who Active window will appear.
10. Verify that the node labeled “192.168.1.10, 1769-L18ERM LOGIX5318ERM” via the AB_ETH-1 Ethernet
driver is selected and click the “Download” button.
The Download window will appear.
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11. When the confirmation window appears, click the “Download” button again.
If you reach this step in the lab but do not end up completing the entire ADC exercise, please notify an
instructor as you leave so that the controller may be reset for the next session.
12. When prompted to confirm switching the controller back to “Remove Run”, click the “Yes” button.
13. Automatic Device Configuration (ADC) may cause the transition to run to be longer. If the following window appears,
click the “OK” button to acknowledge the delay.
Continue to the next section to see ADC in action.
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Demonstrating Automatic Device Configuration
In this section, you will generate a configuration mismatch by changing a parameter on the drive and then reconnecting it. This
will cause the ADC feature to activate and restore the drive to its programmed configuration.
1. Wait for the drive to be configured from the previous download. That will be indicated in Logix Designer by
the following transition:
2. Unplug one of the Ethernet cables between the controller and the drive. This will generate a fault on the
drive.
3. Press the Stop
button to clear the fault from the drive.
4. Using the lessons from the first exercise, change parameter “P033 – Motor OL Current” to 5.0 (or another
value if you desire).
5. Reconnect the Ethernet cable to the drive. This will reinitiate communication between the drive and the
controller, which starts with verifying the configuration signature.
Notice that the PowerFlex 525 drive will get a F048 – Parameters Defaulted fault on the LCD Keypad display after a few
seconds. This is normal and the first step of the Automatic Device Configuration process. The drive is now being
configured.
6. Go back to the I/O Configuration tree in Logix Designer; you will notice a Yellow triangle next to the
PowerFlex 525 drive (PF525_Drive). Click once on the drive to highlight/select it. You will notice that the
drive’s connection status is in a “Configuring” state.
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7. Minimize Logix Designer so that the HMI is visible. On the Startup screen of the HMI, there is a multistate
indicator which shows the connection status of the PowerFlex 525 drive.
It will take about a minute for the PowerFlex 525 drive to be configured.
8. Wait until the ADC process has completed. This will be indicated by the drive’s connection status switching
from “Configuring” to “Running”. Once this occurs, continue to the next step.
ADC will automatically reset (power cycle) the drive as part of the configuration process. This is done
because some parameters require a reset before they take effect. If a drive is being replaced with an out-ofthe-box drive, you will typically see one or more resets during the ADC process.
9. If the machine is currently in the ABORTED state, press the “Clear Faults” button.
After a few moments the state machine should transition to the STOPPED state.
10. Press the “Program/Operator” button until “Program” is displayed. Program mode (AUTO) is now the
active control mode.
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11. Press the “Start” button. The system begins operating according to the Studio 5000 Logix Designer
program.
The same logic from the previous section will be executed.
12. Let the system run for about one minute to see the full cycle of the ladder logic. Once satisfied, press the
“Stop” button.
You can verify that the drive has the correct parameter now loaded for “P033 – Motor OL Current” through the HIM or the
Add-On Profile using techniques you learned earlier this lab.
Reset the System
To disable Automatic Device Configuration, you can either reverse the steps of the previous section, or more easily, download a
new program to the controller that does not have ADC enabled.
1. Close the PF525_Lab_ADC project file. You don’t need to save changes.
2. Open the PF525_Lab project file from the previous lab exercise.
3. Download the PF525_Lab project to the controller, and put it back into “Remote Run” mode when
prompted.
This concludes the lab exercises. Additional information about the Drives and Motion Accelerator Toolkit has been included
for your reading as the next appendix if you are interested in it.
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Appendix: Overview of the DMAT
The Drives and Motion Accelerator Toolkit DVD, publication IASIMP-SP017, was developed around a modular concept.
Modularity lets you decide which components to incorporate into your machine, providing greater flexibility and a custom fit. The
preconfigured logic is specifically designed around this modular concept and consists of three main logic module types.
Logic Module Overview


Machine
o
The machine module contains the high level control for the entire machine. The machine module was built
around a simple state machine that you can customize to fit most applications. The machine module
broadcasts out commands and receives feedback information from each of the application and device
modules. Based on the feedback information, the machine will react accordingly.
o
In addition, the machine module provides a high level interface with the HMI, accepting commands like Start,
Stop, and Clear Faults. It provides status info to the HMI terminal like current state of the machine (for
example, RUNNING versus STOPPED).
Application
o

The application modules contain all of the application specific code. This is where a majority of the
customizing is expected to occur and is essentially a programming space where you spend a significant
portion of your efforts to develop proprietary logic specific to your application.
Device
o
Device modules contain all of the logic to control the essential functions required by the device. This logic
reduces the programming effort required by most applications providing more time for the proprietary logic
needed for the application.
o
Typically, the device module consists of a physical drive, but could also consist of a virtual or feedback-only
axis. Device modules can also consist of multiple devices (for example, a drive) and perhaps a feedback
device (for example, a sensor).
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Machine/Application/Device Module Relationship
The machine module monitors the current state of the overall machine and based on the state and/or requests from the HMI
terminal, broadcasts out commands to both the application and device modules. The individual modules perform a predefined
task based on the command. Some of the commands may be ignored depending on the module type.
Each of the modules are defined as individual programs in the Logix Project.
Each program contains all of the necessary logic to interact with the other configured modules. This interface between each of
the modules is accomplished via the Monitor and Control routines located in each of the programs. The machine commands and
corresponding module status is routed through the Monitor and Control routines. This lets the modules operate independently in
a modular structure.
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Module Routine Overview
Each module is broken down into routines that contain logic for a specific function. Each module contains a monitor and control
routine that provides a common interface between the machine and the application / device modules. Each of the routines main
functions are listed below:
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Machine Module
The machine module contains the high level control for the entire machine. The machine module was built around a simple state
machine that you can customize to fit most applications. The machine module broadcasts out commands and receives feedback
information from each of the application and device modules. Based on the feedback information, the machine will react
accordingly.
In addition, the machine module provides a high level interface with the HMI, accepting commands like Start, Stop, and Clear
Faults. It provides status info to the HMI terminal like current state of the machine (for example, RUNNING versus STOPPED).
Machine States
By default, the machine program module operate based on the below overall state diagram.
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Machine State Diagram
The machine module uses the Transitional States to move between Permanent States. Typically, the machine only remains on a
Transitional State for brief period of time. If the machine module detects an error during a Transitional State or if the application
or device modules fail to transition within an allotted time (10 seconds by default), the machine module issues an ABORT
command. The fail safe transition timer makes sure the overall machine does not become stuck in a Transitional State. It also
helps to provide diagnostic information to determine which module is not transitioning properly.
You can fully customize the state machine, letting you change the relationship between states and the state names, and add or
remove states if needed. Refer to the Drives and Motion Accelerator Toolkit (DMAT) Quick Start publication (iasimp-qs019_-enp.pdf) Appendix B, for information on how to customize the state machine.
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Default Machine States
Default Machine Commands
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Machine Control Module Tags
The machine control data type, UDT_MachCtrl, comprises the overall machine control and status, including the state machine.
The user-defined data type consists of these components.
Machine Tags
Device and Application Status Rungs and Logix
The device and application status rungs provide feedback information to the machine module and consist of these components.
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Device Module Status
Application Module Status
The status bits are set in the Monitor routine of the corresponding modules. These status bits are vital to the machine module, as
they are used to determine the overall status of the machine. They help the machine transition between states or detect a fault
and respond accordingly. All of the module status information is summarized in the Monitor routine of the machine module.
For this Drives and Motion Accelerator Toolkit (DMAT) application example, the rungs are found in the R02_Monitor routine of
the P01_Machine program.
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DMAT Device Status Rungs
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DMAT Application Status Rungs
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Application Modules
The application modules contain all of the application specific code. This is where a majority of the customizing is expected to
occur and is essentially a programming space where you spend a significant portion of your efforts to develop proprietary logic
specific to your application. In this example, application code is shown within the R10_ApplicationCode routine of the
P02_Application program.
In this example below, is only a part of the application code is shown for the DMAT assembly application.
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Device Modules
Device modules contain all of the logic to control the essential functions required by the device. For this DMAT example, we are
using the PowerFlex 753 / 755 HMI faceplate and AOI instruction which has preprogrammed start, stop, speed reference, Accel
and Decel times. This logic reduces the programming effort required by most applications providing more time for the
proprietary logic needed for the application.
Typically, the device module consists of a physical drive, but could also consist of a virtual or feedback-only axis. Device
modules can also consist of multiple devices, for example, a drive and perhaps a feedback device, for example, a sensor.
Device Module Tags
The application and individual device modules interact with each other via device specific control tags that include both
command and status information. The control tags consist of these data types.
All of the data types listed above can be modified to fit specific needs of your application. However, modifications to the data
types could have an impact on the device module and/or other preprogrammed logic, especially during import of additional
device modules.
For example, the UDT_ServoCtrl data type that is used by the integrated motion drives (CIP Motion and Sercos interface based
drives) consists of these tags.
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CIP Motion UDT_ServoCtrl Tag Listing
UDT_ServoCtrl Tag
The user-defined type for the Kinetix 300 drives and the add-on defined data type for the PowerFlex drives serve similar function
as the UDT_ServoCtrl data type, however their layouts differ. Refer to the specific data types for more information.
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Device Module Control Logic
In this example, the R03_Control routine for the P03_PF753_Drive device module initiates and/or clears the Reset and Abort
sequences. It is the same for the R03_Control routine for the P04_PF755_Drive device module.
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Notes
Publication CE-DM253-EN-P — Oct 2014
Copyright© 2014 Rockwell Automation, Inc. All rights reserved.
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