C135 PCS 7 (PCS7)
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Configuring ABB Frequency Inverter Communication Blocks via PROFIBUS DP in PCS 7

Configuring ABB Frequency Inverter Communication Blocks via PROFIBUS DP in PCS 7

To control an ABB frequency inverter (such as ACS800 or ACS880) via PROFIBUS DP in SIMATIC PCS 7, install the manufacturer-supplied GSD file in STEP 7 HW Config, configure a Parameter Process Data Object (PPO) type (e.g., PPO Type 1, 3, or 4), and map the peripheral I/O addresses to an adapter chart in CFC. Because Siemens does not provide a native APL channel driver specifically for ABB drives, engineers decode the ABB Main Control Word (MCW) and Main Status Word (MSW) using standard bitwise logic in CFC and interconnect them to the APL speed-controlled motor block 'MotSpdCL' (FB1854).

Table of Contents

Executive Summary

Variable Frequency Drives (VFDs) from third-party manufacturers, particularly the ABB ACS800 and ACS880 families equipped with RPBA-01 or FPBA-01 communication adapters, are frequently integrated into SIMATIC PCS 7 automation projects. A common engineering obstacle occurs when engineers search the PCS 7 Advanced Process Library (APL) for an 'ABB Driver Block' and find none. While Siemens provides certified drivers for SIMOCODE, SINAMICS, and generic standard telegrams, third-party inverters require configuring standard PROFIBUS PPO profiles and mapping control/status words to APL motor blocks. This guide details the GSD installation, PPO telegram configuration, CFC adapter logic, and WinCC faceplate integration.

Architectural and System Mechanics

ABB Drive Communication and PROFIBUS PPO Architecture:

  • PROFIBUS DP Profile for Variable Speed Drives (PROFIdrive / ABB Drive Profile):
  • PPO Types (Parameter Process Data Objects): Standardized communication telegram structures combining acyclic parameter channels (PKW) and cyclic process data (PZD).
  • Common Selection: PPO Type 4 (6 words PZD, no PKW) or PPO Type 3 (2 words PZD: Control Word + Reference Speed).
  • Word-Level Data Structure:
  • PZD 1 (Output / Control Word): Main Control Word (MCW) commanding Start, Stop, Ramp Hold, and Fault Reset.
  • PZD 2 (Output / Reference): Speed reference normalized from 0 to 20,000 (hex 16#4E20 = 100% rated speed in ABB profile, or 16#4000 = 16384 in standard PROFIdrive).
  • PZD 1 (Input / Status Word): Main Status Word (MSW) reporting Ready to Switch On, Running, Tripped, and At Setpoint.
  • PZD 2 (Input / Actual Value): Actual motor speed feedback.
  • APL Integration: The APL MotSpdCL block manages technological interlocking, operator faceplates, and mode control. An intermediate adapter chart translates MotSpdCL outputs into the bitwise MCW.

Step-by-Step Engineering and Implementation Procedure

Step 1: Install ABB GSD File in STEP 7 HW Config

  1. Download the certified GSD file for the ABB drive adapter (e.g., ABB0812.GSD for RPBA-01 or ABB_0959.GSD for FPBA-01) from ABB.
  2. In HW Config, select 'Options' -> 'Install GSD Files...'.
  3. Browse to the extracted folder, install the GSD, and update the catalog (`Options' -> 'Update Catalog').

Step 2: Configure the ABB Drive on the PROFIBUS DP Line

  1. In the HW Config catalog, locate PROFIBUS DP -> Additional Field Devices -> Drives -> ABB.
  2. Drag the drive slave onto the PROFIBUS DP master line and assign a unique DP address.
  3. In the slave configuration table, insert PPO Type 4 (or PPO Type 3).
  4. Note the peripheral input and output addresses (e.g., Input IW 512..522, Output QW 512..522).
  5. Save and compile HW Config.

Step 3: Create the CFC Adapter Logic for ABB Drive Profile

In CFC, build a reusable sub-chart or SCL block to assemble the Main Control Word:
1. Map MotSpdCL.Fwd / PmpRun to Bit 0 (ON/OFF1) and Bit 3 (ENABLE OPERATION) of the ABB MCW.
2. Ensure Bit 1 (OFF2 - Coast to Stop) and Bit 2 (OFF3 - Quick Stop) are tied to True for normal operation.
3. Map MotSpdCL.RstLi to Bit 7 (FAULT RESET).
4. Scale MotSpdCL.SP_Out (0..100%) to the ABB reference word (0..20000 or 0..16384) using a multiplier block (Mul04).
5. Write the assembled words to output addresses using standard peripheral write blocks or direct I/O assignments.

Step 4: Map Drive Status Words Back to MotL / MotSpdCL

  1. Read input word IW 512 (MSW).
  2. Extract Bit 2 (Running / Operation Enabled) and connect to MotSpdCL.FbkRun.
  3. Extract Bit 3 (Fault / Tripped) and connect to MotSpdCL.Trip.
  4. Read IW 514 (Actual Speed), scale to 0..100%, and wire to MotSpdCL.Rbk (Readback).

Verification

To verify ABB drive communication:
1. In HW Config, switch to online mode; verify that the ABB DP slave icon reports no communication errors.
2. In CFC test mode, command the motor to start from MotSpdCL in Manual mode; confirm that MCW transmits 16#047F (Run) to the drive.
3. Verify that the drive accelerates and reports running status back to MotSpdCL.FbkRun.
4. Test trip behavior: simulate a drive fault; confirm that MotSpdCL.Trip asserts, generating a critical alarm in WinCC.

Limitations and Operational Precautions

Operational precautions:
- Always verify drive parameter settings on the physical ABB keypad: parameter 98.02 (Comm Module) must be set to FIELDBUS, and parameter 10.01/10.02 must point to COMM.CW.
- Emergency Stop circuits must cut power to the drive via hardwired Safe Torque Off (STO) terminals; fieldbus communication commands must never be used as a primary safety trip.
- Be cautious of speed scaling differences: ABB Drive Profile uses 20,000 for 100% speed, whereas standard PROFIdrive uses 16,384 (16#4000). Incorrect scaling can cause 18% speed overspeed errors.

Engineer FAQ

Q: Does Siemens provide a dedicated APL driver for ABB drives?

A: No. Siemens does not provide a branded APL driver for ABB drives. Engineers configure standard PPO telegrams in HW Config and map signals to APL MotSpdCL via CFC logic.

Q: What is the difference between PPO Type 3 and PPO Type 4?

A: PPO Type 3 consists of 2 words of process data (Control Word + Reference). PPO Type 4 contains 6 words of process data, allowing additional monitoring of motor current, torque, and fault codes.

Q: What is the ABB 100% speed reference value?

A: In the standard ABB Drive Profile, 100% nominal speed corresponds to decimal 20000 (16#4E20). In PROFIdrive mode, it corresponds to decimal 16384 (16#4000).

Q: Can ABB drives be controlled over PROFINET in PCS 7?

A: Yes. By installing the ABB FENA-01, FENA-11, or FPNO-21 PROFINET adapter and importing the matching GSDML file into HW Config.

Q: Can I use SFC14 and SFC15 to exchange data with the ABB drive?

A: Yes. If process data length exceeds 4 bytes (e.g., PPO 4 with 12 bytes), use SFC14 (DPRD_DAT) and SFC15 (DPWR_DAT) to guarantee peripheral data consistency.

Technical References

Related Articles

Related Tags

ABB ACS800, ABB ACS880, PROFIBUS PPO, MotSpdCL, VFD Integration

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