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Exporting Hardware and Firmware Inventory Records in SIMATIC PCS 7 via SMMC and HW Config

Exporting Hardware and Firmware Inventory Records in SIMATIC PCS 7 via SMMC and HW Config

To export a comprehensive inventory of installed automation hardware, module types, and actual online firmware versions across S7-400 controllers and ET 200M distributed I/O stations in SIMATIC PCS 7, deploy the SIMATIC Management Console (SMMC) or the free Siemens Assessment Suite - Data Collector (SAS-DC). Standard HW Config 'Station > Export' exports only offline configuration defaults (.cfg) and cannot read actual physical firmware revisions or serial numbers. SMMC connects directly to plant networks, queries electronic Identification and Maintenance (I&M) data from all installed modules, and exports structured hardware inventories to Microsoft Excel.

Table of Contents

Executive Summary

Comprehensive asset auditing is mandatory for cybersecurity compliance, lifecycle planning, and obsolescence management in industrial control facilities. Plant managers and validation engineers frequently require an accurate, tabular record (in Microsoft Excel or CSV format) listing every installed controller card, communication processor, ET 200M interface module, and I/O card, detailing its exact commercial order number (MLFB), hardware revision, and installed firmware version. Engineers frequently attempt to generate this inventory using the built-in Station > Export function in STEP 7 HW Config. However, this native export generates only raw configuration text files populated with offline default catalog data, completely omitting physical module firmware revisions and field modifications. Sourcing authentic hardware inventories requires specialized Siemens asset collection utilities.

Limitations of HW Config Station Export vs Actual Hardware Realities

The native STEP 7 HW Config export tool has severe architectural limits:

  • Offline Default Data Only: When a user adds a module (e.g. 6ES7321-1BL00-0AA0) to HW Config, the database records the baseline catalog description. If the physical module in the field was upgraded to a newer firmware or hardware release, HW Config remains oblivious.
  • No Serial Numbers: Hardware configurations do not record individual module serial numbers or manufacturing dates.
  • Unreadable Format: Station > Export outputs a proprietary .cfg text format intended for station cloning, not for tabular spreadsheet analysis.

Electronic Identification & Maintenance (I&M) Data Architecture

All modern SIMATIC hardware components incorporate non-volatile I&M memory records (PI Standard):

  • I&M 0 (Device Identification): Factory-programmed manufacturer ID, full order number (MLFB), physical serial number, hardware revision counter, and installed firmware version.
  • I&M 1 to 4 (Maintenance Data): Plant location identifiers, installation dates, and maintenance comments.
  • Sourcing authentic inventories requires an automated tool that actively queries I&M records over the network via system record reads (SFC51 / RDREC).

Lifecycle Auditing with SIMATIC Management Console (SMMC)

The SIMATIC Management Console (SMMC) is the official plant lifecycle auditing platform for PCS 7:

  • Dispatches network audit agents to interrogate all central and distributed racks across the Plant Bus.
  • Collects both configured offline data and actual online I&M firmware versions, highlighting discrepancies.
  • Exports comprehensive, multi-tab Microsoft Excel reports detailing CPUs, CPs, ET 200 stations, PC stations, installed software packages, and Automation License Manager licenses.

Hardware Inventory Collection Tool Comparison Matrix

The following table compares tools for collecting hardware and firmware inventory data in PCS 7:

Audit ToolOnline Firmware Collected?Serial Numbers Captured?Multi-Station Plant Audit?Output FormatCost / LicenseSIMATIC Management Console (SMMC)Yes (I&M Direct)YesYes (Entire Plant)Excel (.xlsx)Licensed OptionSiemens Assessment Suite (SAS-DC)Yes (Diagnostic Query)YesYesHTML / ArchiveFree of ChargeHW Config Station > ExportNo (Offline Catalog Only)NoSingle Station OnlyPlain Text (.cfg)Standard STEP 7 ToolHW Config Module InformationYes (Manual Per-Slot)YesSingle Module OnlyPrint / Screen ViewStandard STEP 7 Tool

Step-by-Step Procedure to Export Comprehensive Hardware Inventories

Method 1: Automated Inventory Export via SIMATIC Management Console (SMMC)

  1. Launch the SIMATIC Management Console on the designated Engineering Station or Management PC.
  2. In the console tree, select the target Multiproject or plant network.
  3. Click Determine Inventory Data.
  4. Select the inventory scope: Check Hardware (configured and actual), PC stations, and License keys.
  5. Click Start. SMMC scans all online AS controllers, queries ET 200 active backplanes, and reads I&M data from all modules.
  6. Once data collection completes, click Export to Excel.
  7. Save the resulting workbook; it provides comprehensive worksheets detailing every module MLFB, slot location, serial number, and firmware version.

Method 2: Sourcing Free Inventory via Siemens Assessment Suite (SAS-DC)

  1. Download the Siemens Assessment Suite - Data Collector (Entry ID 65976201) from SIOS.
  2. Extract and launch the executable on the Engineering Station.
  3. Select Collect Hardware Information.
  4. Connect to the active Plant Bus; allow the tool to scan S7-400 CPUs and distributed ET 200M stations.
  5. Export the collected dataset into an HTML report or CSV spreadsheet.

Verification

To verify hardware inventory data integrity:

  1. Discrepancy Audit: In the exported Excel report, compare column 'Configured Firmware' against 'Actual Firmware'. Flag any modules where field firmware is newer or older than configured.
  2. Physical Cross-Check: Inspect a physical ET 200M card in a control cabinet. Confirm that the serial number and firmware printed on the module match the spreadsheet entry exactly.
  3. Completeness Check: Verify that all distributed remote I/O drops (PROFIBUS DP and PROFINET IO) appear in the inventory.

Limitations and Operational Precautions

  • Network Traffic Management: Interrogating I&M records across hundreds of modules generates acyclic communication frames; execute full plant inventory scans during low-activity operational periods.
  • Legacy Module Limitations: Very old legacy modules (manufactured prior to 2002) do not support electronic I&M records; their firmware must be audited from physical front-panel labels.
  • Procurement Disclaimer: When planning hardware upgrades based on inventory audits, validate replacement MLFBs and product discontinuation notices against an authorized Siemens distributor quotation.

Engineer FAQ

Can HW Config 'Address Overview' show firmware versions?

No. The Address Overview tool (View > Address Overview) displays only assigned I/O memory ranges and process image partitions.

Is SIMATIC Management Console included with standard PCS 7?

SMMC software is installed from the PCS 7 installation media, but utilizing its advanced inventory and software deployment features requires dedicated SMMC agent and server licenses.

Can SAS-DC be executed on a running production system?

Yes, SAS-DC executes non-intrusive read-only diagnostic requests that do not impact controller execution or production safety.

Technical References

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Related Tags

  • https://industrialautomation.net/search?query=simatic-pcs7
  • https://industrialautomation.net/search?query=hardware
  • https://industrialautomation.net/search?query=inventory
  • https://industrialautomation.net/search?query=management-console
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