Allen-Bradley

PowerFlex 525
Programming Guide
Rev. 1.2

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 1. Introduction
The Allen-Bradley PowerFlex 525 is a popular VFD due to its versatility and simplistic
programming. Detailed programming will be shown via keypad and computer.
Installation of Connected Components Workbench will be required and access to an
AB1203-USB Device or Ethernet Cable will be required as well.
MHS PN:100645702 AB-1203-USB Device
2. HIM Keypad Explained

When Programming the VFD the information on the left will be displayed. These letters
let you know what parameters group that is currently displayed. Example is if C is
selected on display you will be in the communication portion of the parameters. These
setting will allow you to configure IP Address for unit and how the unit boots up. Each
of parameter in this section deals with how the unit boots on the network.

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 3. Viewing and Editing Parameters
Typically, when the drive is
configured the figure to the
right is displayed. This screen
shows the speed in HERTZ for
VFD.

To exit that menu and get in

programming mode the Esc
key need to be pressed and
the Basic Display Group will be
Displayed, and the parameter
number will Flash.

Press Esc again it will flash the

parameter group.

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 Using the Up and Down arrows
will scroll through the group list
(b, P, t, C, d, A, f, and Gx).
Press enter to enter the group
that is selected. Once selected
the right digit will flash.
Using the Up and Down arrows
to scroll through parameter list.
Press Enter to view the value
of the parameter or Press Esc
to return to the parameter list.
Press Up and Down arrows to
change the parameter value.

Press Esc to cancel changes

or press Enter to save changes
and exit Program Mode.

Press Esc to return to the parameter list. Continue to press Esc to back
completely out of programming menus.

Understanding which parameters control the drive they must be change locally in
order to control drive.
Parameter 46 sets source 1 is
how the drive is controlled.
Selecting Keypad will give
control to display Ethernet will
give network and Serial/DSI will
give control to computer with
AB-1203 Device.

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 Parameter 47 will give control
so for Potentiometer select
Drive Pot, for Ethernet select
Ethernet/IP, and for Serial/DSI
select Serial/DSI.
Parameter A544 [Reverse
Disable] to 1 “Rev Disabled”
This parameter should not be
enabled.

4. Allen-Bradley Connected Components Workbench (CCW)

CCW is software that Allen-Bradley that enables technicians the ability to connect to
equipment via Ethernet and using the AB-1203-USB Device.

CCW is a huge download that can take time it is 5 to 6 gigabytes (depending on

version). Administrative rights are required to install the software on either desktop
or laptop. If using the AB-1203 device the drivers are require in order to be able
utilize the equipment.

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 After download extraction of the package file will need to be performed in order to
complete the installation.

After extracting the files with

package delivery to launch
setup double click Setup.exe.

Installation will take time depending on computer it can take an hour to complete.

Click Install now

and then accept
EULA.

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 What installation
starts you will get
percentage of
completion. There
are points during
installation that will
look like it is not
doing anything, but it
is working in
background give it
time. When
completed you will
get “That’s it!”,
computer will need
to be rebooted prior
to running for first
time.

After installation of CCW now the driver for the AB-1203-USB device (if available)
needs to be installed.
Install 1203
device by
double clicking
installer. You
will get prompt
to right asking
to install.

After installation of the drive the 1203 device needs to be

plugged into the USB port on the computer. Once it is installed opening windows
Device Manager is required in order to determine what COM port it is installed on.
Below shows example of device and COM port in Device Manager.

On the right
shows the
installation
structure it will
be under
Rockwell
Automation in
Windows 10.

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 5. Configuration of 1203-Device
Once program is started the following screen will be presented.

On the toolbar Click Communications the following screen will be displayed next.

The configuration of drivers needs to be

completed in order to use the 1203-device with software so clicking Configure
Drivers.

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 On this screen click down arrow and select RS-232/DF1 devices. One selected click
the Add New button.

After clicking the Add New button the following box will need to be display in this
box the name can be change this document will leave it as default.

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 The above image is configuration for the 1203 Device to be able to use with CCW.
The main things that need to be configured is Comm Port: Found in Device
manager, Device selection needs to be 1770-KF2/1785-KE/SCANport, Baud Rate:
115200.
The 1203-Device is now configured for use and can connect to VFD.

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 6. PowerFlex Connection Ports

Connecting to VFD drive utilizing the 1203 Device will allow connection to VFD
without compromising operation. The connection will be via DSI Port. Connection
via Ethernet will disrupt operation.

AB-1203 Device

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 7. Connecting TO VFD Drive

Connecting to VFD after starting program want to select New on home screen.

Once new is click a box will popup Name This can be name of VFD Location the
default is CCW directory under Documents. Make sure Add Device on Create is
checked then click create.

On Add Device Screen select drive that is being connected to in this example it
will be a PowerFlex 525.

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 Select the PowerFlex 525 then Select. (double clicking does same thing)

Once selected the click

Add To Project

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The Device Definition Screen will be displayed this gives information regarding
firmware and drive information just hit “OK”

This is screen we will use the connect in order to make connection to VFD.

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 Click the Connect button on
drop down menu select
Connect. This will initiate the
connection to VFD.

The following screen will be

displayed. The screen basically
tells the program how you want
to connect to VFD. When
connecting with 1203-Device
click + next to AB_DP1, Data
Highway Plus to expand option
and select AB DSI and hit
continue. If using Ethernet will
be explained in section later.

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 When it is loading a prompt will
be displayed asking if you want
to use Project or Physical. Click
box un Use Physical so it will
download parameters from the
VFD.

When connected you will see green bar showing you are connected.

When selecting
parameters ensure that
PowerFlex 525 is
selected. This will display
all parameters.

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Example of
communication
parameters for IP
Address:
P129: 134
P130: 198
P131: 1
P132: 20

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 8. Connecting Via Ethernet
When connecting via Ethernet the IP Address needs to be known of the PowerFlex
VFD that is being connecting to. The computer used to connect to the VFD will
need the IP Address change in order to complete connection. Generally, the IP
Address of the VFD can be found in schematics for the VFD or a sticker on VFD.

So, in this example if the 525 IP address is 192.168.1.10 you need to set the
computer address 192.168.1.x anything but 10 because that IP is already taken by
VFD. The subnet mask needs to be matched as well. In this example
255.255.255.0 will need to be the same on connecting computer.

When connecting with Ethernet

clicking the plus next to
AB_ETHIP-1.

As with connecting with AB-1203 Device selecting Use Physical and Check Mark
under it and click continue. This will download the parameters from VFD drive and
bring you to screen with green line showing you are connected. Then the interface
will be the same as with AB-1203 Device as described before.

*Note when connecting via Ethernet it will take the drive offline, using 1203 device
will allow you to see the drive while in operation and control if drive is online or
offline.

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 9. Downloading and Uploading Via USB Cable
The program is loaded on the keypad on the PowerFlex 525 but when accessing with
Windows 10 the computer will freeze up. To avoid this issue is to download the
PF52XUSB.EXE program to the computer this will prevent Windows 10 from freezing.

The following cable is needed to connect the keypad to computer.

The first step is to remove the keypad from the drive this is done by pressing release
on top of keypad and sliding lock out.
Slide Forward
Press down

Then pulling the keypad away from the body of the PowerFlex 525. Then want to turn
the keypad around and connect the USB cable to the keypad and computer.

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After connection if the program is already running the following screen will be
displayed. It will show as disconnected.

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Once the drive is connected the Disconnected will change to Connected.

Then the three following choices will be available for selection:

Upload – this option Uploads the configuration from the drive to the computer.
Download – this option Downloads the configuration from the computer to the drive.
Flash – No used unless directed by engineer. (Flash firmware to the drive)

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