Integrating PowerFlex 525 with CompactLogix: A Step-by-Step Ethernet/IP Guide

by Bryan Hellman April 23, 2025

If you’re working with Allen-Bradley’s CompactLogix PLCs and PowerFlex 525 drives, integrating them over EtherNet/IP unlocks powerful advantages, like real-time status monitoring, tag-based control, and faster diagnostics.

But setting it all up correctly can be tricky if you’re new to Logix-based networks or drive profiles. This guide will walk you through the full integration process—from wiring and IP addressing to Studio 5000 configuration and test runs.

Whether you're commissioning new equipment or upgrading legacy connections, this step-by-step guide ensures a smooth and reliable setup.

What You’ll Need

PowerFlex 525 Drive (with firmware 5.01 or later)
CompactLogix PLC (1769 or 5069 series, with Studio 5000)
Ethernet Patch Cables (CAT5e or higher)
Connected Components Workbench (CCW) (optional for initial IP setup)
Studio 5000 Logix Designer (v21 or higher recommended)
Computer with RSLogix or CCW installed
Power supply and circuit protection for both the PLC and drive

Next up: we’ll assign a static IP address to the drive, confirm Ethernet connectivity, and begin the controller-side configuration.

Step 1: Assign the Drive’s IP Address

Before your PowerFlex 525 can communicate over EtherNet/IP, it needs a static IP address. You can set this through the onboard keypad, Connected Components Workbench (CCW), or BOOTP/DHCP software.

Option A: Set IP Address via Keypad (HIM)

Power on the drive
Use arrow keys to navigate to “Addr Cfg”
Set the following parameters:
- P043 – IP Address (e.g. 192.168.1.100)
- P044 – Subnet Mask (e.g. 255.255.255.0)
- P045 – Gateway (if used)
Save changes and reboot the drive

Option B: Set IP via Connected Components Workbench (USB)

Connect your PC to the PF525 using a Micro USB cable
Open CCW and detect the drive
Navigate to Communications Settings and input IP details
Download the changes to the drive

💡 Tip: Choose an IP in the same subnet as your CompactLogix PLC. Example: If your PLC is 192.168.1.10, assign the drive something like 192.168.1.100.

Step 2: Verify Network Connection

Connect the PowerFlex 525’s Ethernet port to the same network switch as the CompactLogix PLC
On your PC, open a command prompt and type:
```
ping 192.168.1.100
```
If you get a successful response, the drive is online and reachable

If ping fails, recheck cabling, subnet alignment, or firewall settings on your PC. You may also need to reboot the drive after assigning the IP.

✅ With the drive now on the network, you’re ready to integrate it into your PLC project in Studio 5000.

Step 3: Add the PowerFlex 525 in Studio 5000

Once the drive is online and responding to pings, you can add it to your CompactLogix project using an Add-On Profile (AOP). This allows seamless tag-based control and status monitoring inside Logix Designer.

A. Download or Confirm the AOP

If this is your first time using a PF525 with Studio 5000, download the latest Add-On Profile (AOP) from Rockwell’s website. Make sure it matches the drive’s firmware version (check P053 on the drive keypad).

B. Add the Drive to the I/O Tree

Open your Studio 5000 project
In the I/O Configuration tree, right-click on the EtherNet/IP module and select “New Module”
Search for and select “PowerFlex 525”
Enter the drive’s IP address (e.g. 192.168.1.100)
Name the drive (e.g. “PF525_Motor1”)
Set the correct firmware version and select “Single Port” if using only one Ethernet connection

C. Configure Connection Settings

Choose whether you want “DPI I/O” (standard control) or “Explicit Messaging” (for diagnostics only)
Define your Input, Output, and Configuration assemblies (default is usually fine)
Set Requested Packet Interval (RPI) — 20–40ms is common for drives
Click “Finish” to add the module

✅ Your drive is now part of the PLC’s I/O configuration and will generate its own tag structure automatically (e.g., PF525_Motor1:O.SpeedRef, :I.Status, etc.).

Step 4: Test the Drive in Studio 5000

Once the drive is in your I/O tree and powered on, you can begin sending it commands directly from the PLC logic. Studio 5000 will automatically generate a tag set for your drive.

Verify Drive Status

Go to Controller Tags in Studio 5000
Find the tag for your drive (e.g., PF525_Motor1:I)
Confirm values are updating (e.g., StatusWord, OutputFreq, Current)

Send Basic Commands

You can now write logic to start/stop the drive, change direction, or control speed using your Output tags:

PF525_Motor1:O.Command — Send start/stop commands
PF525_Motor1:O.SpeedRef — Reference frequency (usually 0–4000 for 0–400.0 Hz)

Optional: Use Diagnostic Tags

The AOP generates a full tag structure, including fault codes, status bits, and feedback.

DriveStatus shows whether the drive is running, faulted, or ready
FaultCode provides active faults numerically
Many engineers use these in an HMI to simplify troubleshooting

Example Ladder Logic Snippet

```ladder | Start_PB Stop_PB | |----] [----+----]/[-----+-----| OTE Start_Command | | +----[ DriveStatus.OK ]----+

Final Tips for a Smooth Integration

✅ Use static IPs for all drives—avoid BOOTP for production systems
✅ Match firmware versions between the drive and AOP for best stability
✅ Label all Ethernet cables and document IP assignments
✅ Back up your drive parameters using Connected Components Workbench (CCW)
✅ Use tag-based control to simplify logic and improve diagnostics in Studio 5000

Once your PowerFlex 525 is online and integrated with CompactLogix, you’ll gain real-time control, fault monitoring, and easier system-wide diagnostics—all without additional analog wiring or hard I/O.

Need Help with Drive Integration?

Whether you're configuring a single drive or building an entire control panel, we’re here to support you with parts, guidance, and rapid delivery.

Industrial Automation Co. has helped thousands of engineers and technicians configure, replace, and scale their systems with Allen-Bradley drives. Let us help you next.

Successfully Added