PowerFlex 525 on Profibus DP with a Siemens S7-300 Processor

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729089 | Date Created: 08/20/2015 | Last Updated: 01/12/2018
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Question

How do I configure Siemens S7-300 Processor to control a PowerFlex 525 drive on

Profibus DP?

Enviroment

 25B PowerFlex 525

 25-COMM-P
 S7-300 Simens Controller

Answer

This application note provides set-up and programming details of the PowerFlex 525 / 523
series drive with the 25-COMM-P Profibus-DPV1 interface using the Siemens S7-300
processor.

All the operations detailed below, assume the user is familiar with the programming of
Siemens PLC's with Step7 software.

This application uses the equipment shown below.

Drive Control Overview

To Control a drive on PROFIBUS we need to map the I/O on the Input / Output image of
the PLC. The PowerFlex 520 series drive uses 16 bit logic control words, reference, logic
status and feedback, and 4 off 16 bit datalinks. The Logic Command word from the PLC
contains 2 bytes of data, whereby each bit has a control significance. See Appendix C of
PowerFlex 25-COMM-P Profibus DPV1 Adapter User Manual, Publication 520COM-
UM004_-EN-E.

So we can start or stop the drive by changing the relevant bits in the Logic Command word.

The drive reference is a 15 bit integer with sign, with a value in 0.01Hz increments is sent
to the drive, up to the [max speed] parameter of the drive. The drive adapter supports up to
4 datalinks, which can be initialized by parameters in the 25-COMM-P adapter. Each
datalink passes a parameter to the drive AND a parameter from the drive. Therefore to
configure a datalink, all that needs to be done, is to set which drive parameter you want the
data to go to / come from.

All the above is accomplished in Cyclic I/O control.

PowerFlex Setup with Connected Components Workbench (CCW) software

Before you insert the 25-COMM-P adapter into the drive, you need to adjust the DIP
switches on the card.

 Set switches on the 25-COMM-P adapter to your Node Address. In this example
address of "04".
 Set DIP SW8 to Big-Endian for Siemens controllers. i.e. sw = closed

This setup assumes that the PowerFlex drive is already setup and tuned for the motor
connected.

1. Launch Connected Components Workbench

2. From the Device Toolbox drag a PowerFlex 525 drive onto the project
3. Click to Connect to the drive. RSLinx Classic window will open.

As we have a PowerFlex 525 drive, so we have an EtherNet connection to the drive. If we

had a PowerFlex 523 drive, then we would need to use the serial interface 1203-USB
connected to the DSI connector with a serial DF1 protocol.
4. Select the PowerFlex 525 drive on EtherNet at node address 192.168.1.20, and
Upload all the parameters.

5. With the PowerFlex 525 tab selected, click on the Parameters button, and scroll
down to change parameters 46 and 47, to select our control and reference to come
from the Network Option card.
6. Change the DataLink settings as shown below for our 25-COMM-P option card.
For Example: The value in parameter C161 is a pointer to parameter P041 [Accel Time1], C162 = P042 [Decel Time], C165 = b003
[Output Current], C166 = b004 [Output Voltage], C167 = b027 [Drive Temp] and C168 = b007 [Fault Code 1].

Once all dataLinks have been configured, then this sets up the communication size in the 25-COMM-P adapter once a reset has been
undertaken (power cycle the drive).

Configuring the Profibus master.

1. Start the Step7 programming software.

2. Unzip the 25-COMM-P_GSD.zip to a folder on your PC, and install the gsd file in the hardware catalogue of Step7.
3. Once the gsd is installed, then you can browse down the hardware catalog for Additional Field Devices …. Drives…AB… 25-
COMM-P.
4. Now drag the 25-COMM-P element from the hardware catalog, onto the Profibus DP master system as below. Select the node
address "04" and click ok.
5. The Ctrl/Stat & Ref/Fb Drv0 (4Bytes) appears on slot 1 of node 4 for the 25-COMM-P option card, and change the I Address
and the Q Address to start at address 90.
6. Additionally drag DataLink 1, & 2, & 3, & 4 to slots 2, 3, 4, 5 adjusting the addresses to be consecutive, as in the following
screenshot.
7. Next Save and Compile from the Station menu, and download to the PLC.
8. To verify the configuration of the drive (4 datalinks set in Connected Components Workbench), matches the configuration of
that just sent down from the hardware configuration, then the PLC SF (System Fault) and BF (Bus Fault) LEDs go from red to
off indicating we have a matched configuration.
9. Additionally when the adapter is correct and communicating with the PLC, then the 3 adapter LEDs on the 25-COMM-P are
steady green.
10. If a mismatch exists, or there is an issue with setup, then you can check the 25-COMM-P parameters in Connected Components
Workbench as shown below. It shows the DLs from/to Net Act = 4 for each.
Controlling the Drive via cyclic I/O control.

The main control block OB1, is used to call the control program FC1. FC1 contains the run logic, and the speed reference to control the
speed of the drive.

The screens below are shown in monitor mode (solid line means logic = true). The logic shows the drive running in the reverse
direction with a speed reference of 24.35Hz.

See the User Manual Appendix C for the significance of the logic command and status bits. The hardware configuration was setup:
Logic Command Word = bytes 90 to 91 Speed Reference Word = bytes 92 to 93 The control word, reference and DataLinks are
compiled into a database, which can be written (DB7) in one pass with a MOV instruction.

The database DB7 is configured:

In the above screenshot, the Speed Reference is provided with a fixed value of 2435, which in 0.1Hz increments is 24.35Hz. In
addition DataLink 1 is provided with a value of 12, which in 0.01s increments is 0.12s Accel Time 1, and DataLink 2 below is
provided with a value of 34, which is 0.34s Decel Time 1.
The drive DataLink values in the above example are:

 DataLink1 Output Current = 0.15 Amps

 DataLink 2 Output Voltage = 88.1 Volts
 DataLink 3 Drive Temp = 25 Degrees C
 DataLink 4 Fault Code 1 = 72 Comms Loss