C135 PCS 7 (PCS7)
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How to Integrate Non-Siemens PROFINET Devices and Field Instruments into PCS 7

How to Integrate Non-Siemens PROFINET Devices and Field Instruments into PCS 7

To integrate third-party, non-Siemens PROFINET field instruments (such as flowmeters, valve manifolds, or weigh feeders from Endress+Hauser, Festo, or Vega) into SIMATIC PCS 7, you must install the manufacturer's certified GSDML file into HW Config and configure driver mapping. While native Siemens instruments benefit from automated PCS 7 module driver generation, third-party GSDML devices lack proprietary Siemens diagnostic structures, causing the driver generator to reject them or generate compile warnings. You resolve this by connecting the device's peripheral I/O words directly to standard Advanced Process Library (APL) channel driver blocks (Pcs7AnIn, Pcs7DiIn) and setting the feature bit to disable automated diagnostic driver insertion, ensuring full faceplate integration and signal status propagation.

Table of Contents

Third-Party PROFINET Support in PCS 7 Architecture

SIMATIC PCS 7 controllers (S7-400 and AS 410-5H) communicate natively with open-standard PROFINET IO devices compliant with IEC 61158 and IEC 61784. Any field instrument bearing official PROFINET certification can exchange cyclic input and output data with a PCS 7 controller.

However, a fundamental architectural difference exists between:
1. Siemens Catalog Hardware (ET 200, SITRANS): Hardcoded inside the STEP 7 hardware catalog. Supported by automated diagnostic blocks (MOD_D1, RACK, OB_BEGIN) generated during CFC compilation.
2. Third-Party GSDML Devices: Defined via XML schema files provided by third-party vendors. The controller reads raw peripheral inputs (PIW) and writes peripheral outputs (PQW), but standard PCS 7 automated diagnostic blocks cannot automatically decode proprietary vendor diagnostic byte layouts.

Installing Manufacturer GSDML Files in HW Config

To add third-party PROFINET devices to your project:

  1. Download the certified GSDML file (*.xml) and associated device bitmap (*.bmp) directly from the device manufacturer's portal.
  2. In SIMATIC Manager, open HW Config.
  3. Close all open hardware stations. Select Options > Install GSD Files.
  4. Browse to the extracted folder, select the GSDML file, and click Install.
  5. Once installation finishes, click Options > Update Catalog.
  6. The third-party device appears in the Hardware Catalog under:
    PROFINET IO > Additional Field Devices > [Manufacturer] > [Device Family].

The Module Driver Generator Challenge with Third-Party GSDMLs

When compiling CFC charts, PCS 7 automatically runs the Generate Module Drivers wizard.
* If a channel driver block (such as Pcs7AnIn or FbAnIn) is interconnected directly to a third-party peripheral address (e.g., PIW 512), the driver generator queries the hardware catalog to locate the parent diagnostics module.
* Because third-party GSDML files do not contain Siemens diagnostic structure definitions, the compiler issues warnings:
W: Module driver could not be generated for address PIW 512.
* If misconfigured, the driver block sets output Bad := TRUE, forcing the process value into invalid status on WinCC faceplates.

Method: Configuring APL Channel Drivers for Non-Siemens Devices

To configure robust signal processing without driver generator errors:

  1. In HW Config, drag the third-party PROFINET device onto the controller's PROFINET IO system.
  2. Assign the PROFINET Device Name and static IP address.
  3. Configure the cyclic data modules (e.g., Input: 4 Bytes Float (IEEE 754) + 1 Byte Status or standard Word Input). Note the assigned peripheral input address (e.g., PIW 512).
  4. Save and compile HW Config, then download to the controller.
  5. In SIMATIC Manager, open the target CFC chart.
  6. Insert the standard APL analog channel driver block Pcs7AnIn (FB1869).
  7. Connect the peripheral address:
    - Interconnect parameter PV_In to the peripheral symbol (e.g., PIW 512).
  8. Disable Automatic Driver Generation for Diagnostics:
    - Set parameter Feature.Bit28 := 1 (Disables diagnostic driver connection requirement, or set MS := 16#80).
    - If using FbAnIn (Fieldbus Analog Input), connect the raw address directly and set parameter Mode := 16#00000201 (IEEE Float with status).
  9. Connect the output PV_Out of the driver block to technological monitoring blocks (such as MonAnL).
  10. Compile CFC charts with Generate Module Drivers checked. The compiler processes the signal without fatal errors.

Verification

To verify that the non-Siemens PROFINET device communicates and updates WinCC:

  1. In HW Config, switch to PLC > Monitor/Modify.
  2. Enter the input address PIW 512 (or PID 512 for 32-bit floats). Verify that raw byte values fluctuate dynamically with process changes.
  3. In the CFC editor, switch to Test Mode:
    - Inspect Pcs7AnIn: confirm that PV_Out.Value displays the converted engineering units (e.g., 124.5 m3/h).
    - Confirm that PV_Out.ST displays 16#80 (Good signal status).
    - Verify that Bad is FALSE.
  4. Open the associated MonAnL faceplate in WinCC Runtime. Confirm that the process value renders without colored diagnostic error banners.

Limitations and Operational Precautions

  • Device Name Matching: PROFINET assigns addresses based on the PROFINET Device Name, not the IP address. The name assigned in HW Config must match the physical device name set via Proneta or web management byte-for-byte; names must be lower-case without spaces.
  • Firmware GSDML Revision: Always use the GSDML file corresponding exactly to the installed device firmware revision. Using a newer GSDML on an older instrument can result in cyclic I/O module rejection (Configuration Fault LED on the instrument).
  • Acyclic Parameterization (Record Data): Reading vendor-specific calibration parameters or secondary variables acyclically requires standard S7 system functions (SFB 52 RDREC / SFB 53 WRREC) rather than automatic APL faceplate tabs.

Engineer FAQ

Can I use SIMATIC PDM to calibrate non-Siemens PROFINET instruments?
Yes. SIMATIC PDM supports third-party instruments provided that the manufacturer delivers an Electronic Device Description (EDD) or FDI device package.

Why does PROFINET communication fail even though the IP address is correct and pingable?
In PROFINET IO, the controller establishes communication based strictly on the station's symbolic device name. If the device name in the physical device does not match HW Config, the controller will not connect, even if the IP address responds to ping.

How is a 5-byte HART-over-PROFINET float structure decoded?
The first 4 bytes contain the IEEE 754 single-precision floating-point number (big-endian), and the 5th byte contains the IEC 61158 quality status byte. Use FbAnIn to unpack both simultaneously.

Technical References

  • Siemens Industry Online Support Entry ID 109742323: SIMATIC Process Control System PCS 7 Engineering System Manual
  • SIMATIC PCS 7 PROFINET IO System Description (Document No. A5E02779836)
  • Siemens Industry Online Support Entry ID 109809264: Integration of Third-Party Devices into SIMATIC PCS 7

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Related Tags

  • https://industrialautomation.net/search?query=profinet
  • https://industrialautomation.net/search?query=gsdml
  • https://industrialautomation.net/search?query=simatic+pcs7
  • https://industrialautomation.net/search?query=instrumentation
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