C135 PCS 7 (PCS7)
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How to Integrate Pepperl+Fuchs Remote I/O and FieldConnex Systems into SIMATIC PCS 7

How to Integrate Pepperl+Fuchs Remote I/O and FieldConnex Systems into SIMATIC PCS 7

To integrate Pepperl+Fuchs (P+F) remote I/O stations (LB/FB systems) and FieldConnex fieldbus diagnostic gateways into SIMATIC PCS 7, engineers should utilize the officially validated Pepperl+Fuchs PCS 7 Add-on Driver Library rather than generic GSD files. The P+F driver package installs custom hardware profiles into HW Config, block libraries into STEP 7, and graphic faceplates into WinCC. During CFC compilation, the PCS 7 Driver Generator (Generate Module Drivers) automatically detects P+F remote I/O modules, instantiates diagnostic function blocks within system @ charts, links them to higher-level rack blocks, and populates the WinCC Maintenance Station with detailed physical and electrical health diagnostics. Always verify library version compatibility against your specific PCS 7 release with an authorized distributor.

Table of Contents

Pepperl+Fuchs Remote I/O Architecture in SIMATIC PCS 7

Pepperl+Fuchs provides specialized remote I/O and physical-layer fieldbus infrastructure engineered for hazardous process areas:

1. LB Remote I/O System

Designed for mounting in Zone 2 / Class I, Division 2 areas or safe areas. Backplanes accommodate hot-swappable I/O modules connecting intrinsically safe field devices in Zone 0/1.

2. FB Remote I/O System

Housed in explosion-proof / flameproof enclosures certified for direct installation inside Zone 1 / Class I, Division 1 hazardous locations.

3. FieldConnex Physical Layer Diagnostics

Diagnostic gateways and power hubs that monitor PROFIBUS-PA or FOUNDATION Fieldbus physical layer health, measuring bus voltage, noise, jitter, and ground faults.

Integrating these systems into SIMATIC PCS 7 requires deep diagnostic interoperability so that field faults, wire breaks, and module unseating trigger standard APL faceplate alarms and Maintenance Station maintenance requests.

P+F Add-on Driver Library vs Generic GSD Integration

When connecting P+F remote I/O to an S7-400 or CPU 410-5H controller, engineers face two distinct integration paths:

Generic GSD File Integration (Basic I/O Only)

Importing standard PROFIBUS-DP or PROFINET GSD files allows the controller to read and write cyclic process data. However, the PCS 7 Driver Generator cannot recognize the proprietary diagnostic records of the P+F modules. Consequently:
* No diagnostic blocks are auto-inserted into @ charts.
* Channel blocks (Pcs7AnIn, Pcs7DiIn) do not receive hardware quality codes (Quality = 16#80 remains static even if a field wire breaks).
* Faceplates fail to display maintenance status.

Pepperl+Fuchs PCS 7 Driver Library (Full Native Integration)

The P+F PCS 7 Driver Library provides complete driver generator integration:
* Custom XML driver generator description files instruct the PCS 7 compiler how to wire diagnostic blocks.
* Auto-generated diagnostic blocks (MOD_PFLB, MOD_PFFB) capture module pull/plug events, field wire breaks, short circuits, and communication loss.
* Seamless integration into SIMATIC WinCC OS and PCS 7 Maintenance Station (MS) with native faceplates matching APL ergonomics.

Step-by-Step Installation and Driver Generator Configuration

Follow this engineering sequence to deploy the Pepperl+Fuchs driver package:

Step 1: Install Software Packages on Engineering Station

  1. Close SIMATIC Manager, STEP 7, and WinCC.
  2. Run the official Pepperl+Fuchs PCS 7 Library setup matching your exact PCS 7 version (e.g., V8.1, V8.2, or V9.x).
  3. The installer installs:
    * Slave catalog descriptions into STEP 7 HW Config.
    * Diagnostic block libraries (FBs, FCs, and UDTs) into the STEP 7 global library path.
    * XML metadata rules into Siemens\STEP7\S7DATA\DRIVER\.
    * WinCC block icons and faceplates (@PG_MOD_PFLB.pdl, etc.) into the OS template directory.

Step 2: Configure Hardware in HW Config

  1. Open HW Config on the AS controller.
  2. In the hardware catalog, browse to PROFIBUS-DP / PROFINET IO -> Additional Field Devices -> I/O -> Pepperl+Fuchs.
  3. Insert the P+F Com Unit (e.g., LB8103 / FB8206) onto the redundant fieldbus line.
  4. Slot the required I/O modules into the virtual rack and assign diagnostic base addresses.
  5. Save and compile HW Config.

Step 3: CFC Compilation and Driver Generation

  1. In CFC, place standard APL channel driver blocks (Pcs7AnIn, Pcs7DiIn) and interconnect their pv_in / pv_out parameters to the P+F peripheral addresses.
  2. Execute Compile Charts as Program.
  3. Ensure 'Generate Module Drivers' is selected.
  4. The driver wizard automatically generates @ charts containing P+F diagnostic blocks interconnected to the channel drivers.

WinCC and Maintenance Station Diagnostic Integration

To enable operator and maintenance visualization:

  1. OS Project Editor: Run the WinCC OS Project Editor on all OS Servers and Maintenance Stations to ensure base screen layouts and alarm scripts are updated.
  2. Transfer Faceplates: Copy the P+F graphic files (@PG_MOD_*.pdl, @PL_MOD_*.pdl) and C-scripts from the P+F library installation directory into the <Project_Dir>\GraCS folder of each OS.
  3. Compile OS: In SIMATIC Manager, perform an OS compilation. WinCC Tag Management will instantiate diagnostic structure tags and alarm definitions automatically.
  4. Maintenance Station Generation: In the Maintenance Station plant hierarchy, execute diagnostic screen generation. P+F remote I/O stations will appear in the MS overview tree under distributed I/O racks.

Pepperl+Fuchs System Component and Integration Matrix

The following table outlines the hardware lines, driver library packages, and diagnostic capabilities:

Product FamilyHazardous Zone RatingPrimary Gateway / ModulePCS 7 Driver SupportSupported Diagnostic ScopeLB SystemZone 2 / Class I Div 2LB8103 PROFIBUS CouplerNative P+F PCS 7 LibraryWire break, short circuit, module unseatedFB SystemZone 1 / Class I Div 1FB8206 PROFIBUS CouplerNative P+F PCS 7 LibraryRedundant power, module fault, communication lossFieldConnexZone 1 / Zone 2HD2-GT-DP Diagnostic GatewayFieldConnex Diagnostic DTMPhysical layer jitter, noise, shield imbalanceGeneric GSDApplication DependentStandard P+F SlaveManual logic onlyRaw I/O data only; no automatic @ charts

Always validate software license requirements and library compatibility with an authorized Siemens and Pepperl+Fuchs distributor.

Verification

To verify successful integration of the Pepperl+Fuchs driver library:
1. In CFC, open the auto-generated @ chart for the AS station; confirm that P+F diagnostic blocks (MOD_PFLB or equivalent) are instantiated and linked to channel blocks.
2. In HW Config online, verify that the P+F coupler and all slotted I/O modules show 'Online: OK'.
3. Physically disconnect a field sensor wire from a P+F input terminal; confirm that the input channel block asserts Bad = TRUE and that the signal status changes to invalid (ST = 16#00).
4. On the WinCC OS, verify that the block icon displays a maintenance symbol and that the diagnostic faceplate identifies the exact slot and channel fault.

Limitations and Operational Precautions

  • Never mix different versions of the P+F driver library across multi-project AS controllers; harmonize library versions before compilation.
  • Ensure FB numbers used by the P+F library do not collide with user function blocks or third-party add-on ranges in the SIMATIC block folder.
  • Installing a generic STEP 7 GSD over an existing P+F PCS 7 library profile can corrupt driver wizard XML associations.
  • Always validate final license quantities, module availability, and MLFBs against the applicable Siemens and Pepperl+Fuchs catalog.

Engineer FAQ

Where can I obtain the Pepperl+Fuchs PCS 7 Driver Library?

The driver library is obtained directly from Pepperl+Fuchs or via authorized distributor channels, typically supplied with installation media and an engineering software license.

Can I use standard PCS 7 APL channel blocks with P+F remote I/O?

Yes. When the P+F driver library is installed, standard APL channel blocks like Pcs7AnIn and Pcs7DiIn connect seamlessly to P+F I/O addresses with full automatic module driver generation.

Does the P+F library support redundant PROFIBUS-DP couplers?

Yes. The P+F library fully supports redundant optical and copper PROFIBUS-DP couplers, automatically generating redundancy diagnostic monitoring blocks.

Technical References

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Related Tags

  • Pepperl+Fuchs
  • Module Drivers
  • LB Remote I/O
  • Driver Wizard
  • Maintenance Station
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