Ensure you have the following materials before starting the setup process:

• Allen Bradley PowerFlex 525 (V5.001 or newer)
• Laptop with Connected Components Workbench (CCW) installed
• Ethernet cable
• One Motion P/N Technical Data Sheet

Connected Components Workbench (CCW) is essential for configuring the PowerFlex 525. To download it:

1. Visit the Rockwell Automation website.
2. Create or log in to an Allen Bradley account.
3. Navigate to the software downloads section and select the latest CCW version.
4. Follow the installation prompts to complete the setup.
5. Contact Allen Bradley Support for any issues during the process.

Proper wiring is critical for safe and effective operation. Refer to the official Allen Bradley PowerFlex 525 manuals:

• PowerFlex 520-Series Adjustable Frequency AC Drive Manual
• PowerFlex 520-Series Parameter List
• PowerFlex 520-Series Quick Start Guide

Note: If links are unavailable, search for “PowerFlex 525” on the Rockwell Automation website or contact support.

Setting up the PowerFlex 525 for Ethernet connectivity involves configuring a static IP address (e.g., 192.168.1.71, subnet mask 255.255.255.0). Follow these steps:

1. Open CCW and establish a connection with the PowerFlex 525.
2. Navigate to parameter C128 and set it to 1 (Static IP).
3. Configure the IP address parameters:
   • C129: 192
   • C130: 168
   • C131: 1
   • C132: 71
4. Configure the subnet mask parameters:
   • C133: 255
   • C134: 255
   • C135: 255
   • C136: 0
5. Power cycle the PowerFlex 525 to apply changes.
6. Verify parameters C128–C136. If unchanged, repeat the steps.
7. Connect your computer to the PowerFlex 525 using an Ethernet cable.
8. Configure your computer’s Ethernet settings (e.g., for Windows 11, search “Ethernet settings” in the Start menu).
9. Test connectivity by running ping 192.168.1.71 in CMD. Look for “Reply from 192.168.1.71”.

Note: Adhere to your organization’s IT policies for network setup. Contact Allen Bradley Support if connectivity issues persist.

Configure the PowerFlex 525 parameters based on the One Motion Product Driver Data spec sheet. Use CCW to set the following parameters for optimal performance:

To request product data sheets and part information contact Technical Support

Auto-tuning optimizes performance by adjusting dynamic parameters. Follow these steps:

1. In CCW, set P040 to 2 (Rotate Tune).
2. Disconnect from all mechanical loads, such as belts or pulleys.
3. Press the green button on the PowerFlex 525 to initiate auto-tuning.
4. Check the values of P484 and P485 after tuning completes.
5. If auto-tuning fails with a fault, adjust P484/P485 to Full Load Amps + 1.0 Amps, increment by 0.2 Amps if needed, and retry.
6. Once auto-tuning is successful, reattach the motor to its load.

Note: Auto-tuning may cause vibration and adjusts parameters like A501–A504 (PM IR Voltage, IXd/IXq Voltage, BEMF Voltage).

Use the following parameters to diagnose and resolve common issues with One Motion PM Products. Adjust incrementally to prevent damage:

Tip: Test after each parameter change to evaluate its impact. Document changes to track their effects.

Configure these advanced parameters to protect the motor from overheating, overcurrent, and other potential issues:

Note: Make incremental adjustments and consult Allen Bradley’s PM motor control documentation for detailed guidance.

Below are solutions to common issues encountered during setup and operation:

• Motor drifts on start: Set A516 to 1 (HFI) to correct rollback or roll forward issues.
• Motor stalling: Gradually increase A531 (Start Boost) by 1% until the motor starts reliably.
• Overload fault on start: Increase P041 (Accel Time) by 2–5 seconds or adjust A532 (Break Voltage) by ±5%.
• Speed fluctuations: Increment A581 (PM Stable 1 Freq) by 2 to smooth VFD output.
• Overvoltage fault on stop: Increase P042 (Decel Time) by 2–5 seconds to prevent overvoltage faults.
• Cyclic current fluctuations: Set A587/A588 (PM Efficiency) to 1900% to stabilize current.

Additional Support:
Consult the PowerFlex 525 Manual for additional information.
Contact Technical Support for further assistance.