Upgrading Industrial Drives Education: Integrating Legacy PowerFlex 700 with ControlLogix via EtherNet/IP

This paper presents the design and implementation of four new laboratory experiments aimed at enhancing the teaching of Industrial Motors and Drives for engineering technology students.The experiments employ Allen-Bradley PowerFlex 700 vector-controlled variable frequency drives (VFDs), originally configured with 20-COMM-D DeviceNet communication adapters.A recent firmware upgrade to the ControlLogix control system rendered these adapters incompatible, prompting migration to Ethernet-based communication, which offers broader industry adoption and improved security.However, with the PowerFlex 700VC drives discontinued and budget limitations preventing the purchase of newer Ethernet-enabled VFDs, the existing drives were temporarily limited to operation via the Human Interface Module (HIM), restricting their functionality.To restore full control capability, 20-COMM-E Ethernet communication adapters were procured, enabling integration with the updated control system.This upgrade required revisions to laboratory documentation and the incorporation of Connected Components Workbench (CCW) into the curriculum, ensuring students gain hands-on experience with modern industrial communication protocols and advanced drive control features.