C135 PCS 7 (PCS7)
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How to Integrate Danfoss VFDs into Siemens PCS 7 Using the APL FbDrive Block

To integrate a Danfoss Variable Frequency Drive (VFD)—such as an VLT AutomationDrive FC 202 or FC 302—into a Siemens SIMATIC PCS 7 project, configure the drive in HW Config using standard cyclic telegrams (Telegram 1 or Telegram 20) via PROFIBUS DP or PROFINET. Connect the hardware input address of the first Process Data Word (PZD1) directly to the PZDIn1 input of the Advanced Process Library (APL) channel block FbDrive (FB1721) in Continuous Function Chart (CFC). When you compile the CFC chart with the Generate module drivers option enabled, PCS 7 automatically creates and interconnects the required system driver blocks (MOD_PPO or MOD_PAL).

Table of Contents

Technical Cause: Why Custom Drive Integration Blocks Fail

Manually mapping raw PROFIBUS DP or PROFINET I/O addresses using custom logic or generic driver blocks frequently introduces faults in PCS 7 applications. Hand-written driver logic fails to integrate cleanly with the native PCS 7 maintenance station, misinterprets rack/slot diagnostic interruptions, and neglects the automatic driver generation mechanism managed by the PCS 7 system compiler.

Using the native APL channel block FbDrive (FB1721) resolves these integration risks. FbDrive implements standard Siemens process data profile (PPO/Telegram) structures. When combined with the driver generator in SIMATIC Manager, FbDrive manages fieldbus communication errors, diagnostic messages, and drive state sequencing without custom code.

Plaintext

+---------------------------------------------------------------------------------+
|                               SIMATIC PCS 7 CFC                                 |
|                                                                                 |
|  +---------------------+        Auto-Generated        +----------------------+  |
|  |  HW Config Station  |      by Driver Generator     |   FbDrive Channel    |  |
|  |  (GSD / GSDML File) |                              |     Block (FB1721)   |  |
|  |                     |                              |                      |  |
|  | Danfoss FC 302      |                              |                      |  |
|  | Telegram 1 (2/2)    |                              |                      |  |
|  | PZD1 In:  IW 512   |==========(Automatic)========>| PZDIn1               |  |
|  | PZD1 Out: PQW 512  |<=========(Automatic)=========| PZDOut1              |  |
|  +---------------------+                              +----------------------+  |
+---------------------------------------------------------------------------------+

Prerequisites

Before configuring a Danfoss VFD in PCS 7, ensure the target system meets the following requirements:

  • Engineering System: SIMATIC PCS 7 V8.0 or higher with Advanced Process Library (APL) installed.
  • Hardware Interface: Danfoss VFD (FC 202, FC 302, or similar) equipped with a PROFIBUS DP option card (MCA 101) or a PROFINET option card (MCA 120).
  • Configuration Files: Corresponding GSD file (for PROFIBUS DP) or GSDML file (for PROFINET) downloaded from Danfoss and installed in SIMATIC Manager HW Config.
  • Standard Profiles: Machine parameters configured to use Standard Telegram 1 or Standard Telegram 20 within the Danfoss control panel.

Implementation Workflow for Integration via APL FbDrive

Integrating a Danfoss VFD into a PCS 7 project requires installing fieldbus configuration files, defining HW Config slot structures, and linking hardware signals within the CFC editor.

Procedure

  1. Install Fieldbus Configuration Files:

    • Download the required GSD/GSDML file package from the Danfoss website.
    • Open HW Config in SIMATIC Manager, navigate to Options > Install GSD File..., select the file directory, and complete the installation.

    • Update the hardware catalog to locate the Danfoss drive object.
      2. Configure Drive Hardware in HW Config:

    • Insert the Danfoss station onto your PROFIBUS DP subnet or PROFINET IO system.

    • Add Standard Telegram 1 (or Standard Telegram 20) to the module configuration slot.

    • Verify that the assigned input address range matches the output address range (e.g., Input Word IW 512 to IW 515 and Output Word PQW 512 to PQW 515).
      3. Instantiate the FbDrive Block in CFC:

    • Open your PCS 7 Continuous Function Chart (CFC) editor.

    • Drag the channel block FbDrive (FB1721) from the APL library folder into the CFC chart.
      4. Connect Primary Process Data Words:

    • Interconnect the first input word of the drive configuration (PZD1, e.g., IW 512) directly to the PZDIn1 parameter of the FbDrive block.

    • Do not manually map remaining process data inputs (PZDIn2...PZDIn6) or output addresses unless non-standard cyclic words are used; the module driver generator completes the remaining signal bindings automatically.
      5. Generate Module Drivers:

    • Open the Compile Program dialog in SIMATIC Manager or CFC editor.

    • Ensure the Generate module drivers checkbox is enabled.
    • Execute CFC compilation. The compiler creates the upstream diagnostics and driver management blocks (MOD_PPO or MOD_PAL) and wires the output addresses (PZDOut1, etc.) automatically.

Standard Telegram Parameter Mapping

The APL FbDrive block operates on strict cyclic structure conventions. Standard Telegram 1 uses two 16-bit input words and two 16-bit output words:

Process Data WordSignal DirectionStandard FunctionFbDrive Parameter MappingPZD1 (Output)Master to DriveMain Control Word (STW1)PZDOut1 (Managed via driver block)PZD2 (Output)Master to DriveSpeed Setpoint (N2: -100% to +100%)PZDOut2 / Setpoint InputsPZD1 (Input)Drive to MasterMain Status Word (ZSW1)PZDIn1 (Assigned in CFC to IWxxx)PZD2 (Input)Drive to MasterActual Speed Feedback (N2)PZDIn2 (Auto-mapped during compilation)

Verification

To verify that the Danfoss drive is integrated correctly in the PCS 7 project:

  1. Check Driver Generation Log: Confirm that the CFC compilation log indicates successful module driver generation without missing hardware address errors.
  2. Validate Fieldbus State: Inspect HW Config online; the Danfoss node icon must show normal operational status without red fault slashes or configuration mismatches.
  3. Verify HMI Control Interlocks: Open the generated APL FbDrive faceplate on the OS Runtime. Check that the command states (Start, Stop, Setpoint) reflect accurately in the VFD status words and physical motor motion.

Limitations and Operational Cautions

  • Supported Telegram Constraints: The PCS 7 FbDrive block natively supports only Standard Telegram 1 and Standard Telegram 20. Non-standard telegram formats require custom APL channel block wrappers or manual data parsing logic.
  • Extended Process Readings: Standard Telegram 1 transmits only the Control/Status Words and Speed Setpoint/Feedback. Advanced electrical measurements (e.g., motor current, power, DC bus voltage) cannot be read via standard cyclic Telegram 1 data. Reading these parameters requires configuring custom PPO types, adding peripheral acyclic read blocks (e.g., RDREC), or utilizing a specialized third-party PCS 7 library block.
  • Address Symmetry: In HW Config, the starting address for input words must match the starting address for output words assigned to the drive telegram slot. Mismatched ranges can cause module driver generation failures during compilation.

Engineer FAQ

Can I read active motor current and consumed power using the Standard Telegram 1 setup?

No. Standard Telegram 1 contains only two 16-bit process data words in each direction (Control Word/Status Word and Speed Setpoint/Feedback). To read auxiliary parameters like output current, operating power, or motor torque continuously, you must configure extended process data words (such as PPO types with additional PZD words) or use acyclic reading functions (RDREC).

How do I handle third-party Danfoss drives that require full PCS 7 Maintenance Station support?

Siemens Industry Services provides official third-party integration libraries for Danfoss drives that include custom faceplates, diagnostic blocks, and native PCS 7 Maintenance Station monitoring assets. These packages can be requested directly from Siemens field service engineering ([email protected]).

Why does the module driver generator fail to link the Danfoss VFD automatically?

Module driver generation typically fails when the drive's I/O input and output start addresses in HW Config are not set identically, or when a non-standard telegram is selected that is incompatible with the APL FbDrive block definitions.

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