C135 PCS 7 (PCS7)
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How to Resolve the Cannot Install GSD File Error in PCS 7 HW Config

How to Resolve the Cannot Install GSD File Error in PCS 7 HW Config

To resolve the "Cannot install GSD file" error in SIMATIC PCS 7 and STEP 7 Hardware Configuration (HW Config), close all open station hardware configuration windows within the HW Config editor while leaving the main editor application frame running. STEP 7 locks the internal hardware catalog database against modification whenever an active station (e.g., SIMATIC 400(1)) is open for editing, causing the Install GSD Files menu item to be grayed out or aborting installation with access violation dialogs. By clicking the inner window close button (the lower "X" icon) to close the active station canvas without exiting HW Config, the catalog database unlocks, allowing engineers to install, validate, and catalog new GSD/GSDML device descriptors cleanly.

Table of Contents

Why STEP 7 HW Config Locks the Hardware Catalog Database

In SIMATIC Manager, the Hardware Configuration tool manages complex relational catalogs containing thousands of Siemens and third-party fieldbus devices:
- Shared Catalog Database: The hardware catalog (*.dat and index files in the STEP 7 system directories) is shared across all configured projects.
- Dynamic Schema Locking: When an engineer opens an AS station, HW Config opens the catalog database in shared read mode and establishes transactional locks on device descriptors.
- Preventing Corrupted Configurations: If STEP 7 permitted installing or replacing GSD files while an active station configuration was open, changes to module profiles could corrupt device parameter tables and invalidate active rack configurations.
- The Enforcement Rule: The menu command Options -> Install GSD File... is strictly disabled or throws an operational rejection error unless all active station canvases are closed.

The Inner vs. Outer Window Interface Distinction

A frequent point of confusion for automation engineers is how to close the station configuration without completely closing the HW Config application:
- The Outer Window "X": Located at the very top-right of the desktop window title bar. Clicking this closes the entire HW Config application and returns to SIMATIC Manager.
- The Inner Window "X": Located directly below the main title bar on the menu/toolbar strip. Clicking this closes only the currently active station document canvas (SIMATIC 400(1) (Configuration) -- ProjectName).
- The Correct State: When the inner window is closed, the main HW Config window remains open with an empty gray canvas, and the menu bar simplifies. In this idle state, the catalog database is unlocked.

┌─────────────────────────────────────────────────────────────[─][口][X] ◄── Outer X (Do NOT click)
│ HW Config - [ProjectName]                                            │
├──────────────────────────────────────────────────────────────────────┤
│ Station  Edit  Insert  PLC  Options  Window  Help                    │
├─────────────────────────────────────────────────────────────[─][口][X] ◄── Inner X (CLICK THIS)
│ ┌──────────────────────────────────────────────────────────────────┐ │
│ │ Active Station Canvas: SIMATIC 400(1)                            │ │
│ │ (Rack 0, Power Supply, CPU 410-5H, CP 1623...)                   │ │
│ └──────────────────────────────────────────────────────────────────┘ │
└──────────────────────────────────────────────────────────────────────┘

Method: Step-by-Step Procedure to Install GSD/GSDML Files

Follow this standardized workflow to install new GSD files (e.g., for SINAMICS G120 variable frequency drives or third-party instruments):

Step 1: Prepare the GSD/GSDML Source Files

  1. Extract the downloaded archive containing the device descriptors into a local folder (e.g., C:\GSD_Temp\SINAMICS_G120).
  2. Verify that the folder contains:
    - The GSD file (*.gsd for PROFIBUS DP, or *.xml / gsdml-*.xml for PROFINET IO).
    - The associated bitmap graphics file (*.bmp or *.dib representing the device icon).

Step 2: Unlock the Catalog in HW Config

  1. In SIMATIC Manager, double-click Hardware to launch HW Config.
  2. Observe the inner window displaying your controller rack.
  3. Click the Inner "X" in the upper-right corner of the inner station window (or select Station -> Close).
  4. Result: The rack layout disappears, leaving an empty gray workspace.

Step 3: Install the GSD File

  1. Select menu Options -> Install GSD File....
  2. In the dialog box, set the source path to From the directory, and browse to C:\GSD_Temp\SINAMICS_G120.
  3. The table populates with the detected GSD files, displaying device names, release versions, and file languages.
  4. Select the target file (e.g., GSDML-V2.35-Siemens-Sinamics_G120-20220115.xml).
  5. Click Install.
  6. The system copies the files to the STEP 7 system repository and registers the bitmap icons. A confirmation prompt confirms: Installation was completed successfully.

Step 4: Update the Hardware Catalog

  1. Click Close to exit the installation window.
  2. Select menu Options -> Update Catalog.
  3. STEP 7 scans the repository, builds new binary indices, and refreshes the catalog tree.

Step 5: Re-open the Station Configuration

  1. Select Station -> Open... and select your AS station (or return to SIMATIC Manager and double-click Hardware).
  2. Expand the Hardware Catalog:
    - For PROFIBUS: Navigate to PROFIBUS DP -> Additional Field Devices.
    - For PROFINET: Navigate to PROFINET IO -> Additional Field Devices -> Drives -> SINAMICS.
  3. Drag the newly installed drive module onto the fieldbus line.

Resolving Post-Installation Catalog Update and Parsing Failures

If the installation aborts despite closing the station canvas, evaluate secondary system locks:
* Multiple Open Projects: Check if SIMATIC Manager has multiple projects or libraries open simultaneously that reference HW Config stations. Close all secondary projects.
* Corrupted Catalog Cache: If HW Config crashes during "Update Catalog", the internal index cache may be corrupted. Close STEP 7, navigate to C:\Program Files (x86)\Siemens\Step7\S7DATA\GSD, back up the folder, and delete the temporary index file GSD_INDEX.DAT. Re-opening HW Config forces a clean catalog rebuild.
* Special Characters in GSD File Path: Ensure the path to the temporary extraction folder contains strictly standard ASCII alphanumeric characters. Non-English unicode paths or spaces can cause parsing failures.

Verification

To confirm that the device is successfully integrated:
- In the HW Config catalog search bar, type the device name (e.g., G120): confirm that the catalog locates the node instantly under Additional Field Devices.
- Drag the drive onto the PROFINET or PROFIBUS network line: confirm that HW Config assigns an IP address and device name without schema syntax errors.
- Open the device properties: verify that communication submodules (e.g., Standard Telegram 1, Telegram 352) populate the configuration table.
- Execute Station -> Save and Compile: confirm that HW Config finishes compilation with 0 errors.

Limitations and Operational Precautions

  • Never Delete Standard Siemens GSD Files: Do not delete default GSD files located in the S7DATA\GSD directory; removing standard files corrupts default catalog typicals.
  • GSDML Version Compatibility: Verify that the PROFINET GSDML schema version is supported by your installed STEP 7 version (e.g., STEP 7 V5.6 supports up to GSDML Schema V2.35). If installing a Schema V2.4 file on an older STEP 7 release, download the backward-compatible V2.33 version from the vendor.
  • Network Master Consistency: If the new GSD device is deployed in a redundant S7-400H network, ensure the GSD file includes redundancy support specifications (e.g., PROFINET System Redundancy S2).

Engineer FAQ

Why can't I install GSD files directly from SIMATIC Manager?

The GSD installation engine is integrated exclusively within the Hardware Configuration editor (s7hcfgx.exe). SIMATIC Manager acts as the project navigator, but does not contain the catalog compilation parser.

What should I do if the Install GSD File option remains grayed out?

Check the Windows taskbar for hidden or minimized HW Config windows. If a background station editor is open on another monitor or virtual desktop, the database lock remains active.

Where does STEP 7 store installed GSD files on the hard drive?

Installed GSD files are copied permanently to:
C:\Program Files (x86)\Siemens\Step7\S7DATA\GSD
Installed device bitmap graphics are stored in:
C:\Program Files (x86)\Siemens\Step7\S7DATA\NSBMPS

Can I install GSD files while the plant is in operation?

Yes. Installing GSD files modifies only the engineering catalog on the engineering station (ES). It does not affect active controller memory until the new device is inserted into HW Config and downloaded to the CPU.

Technical References

  • Siemens Industry Online Support: SIMATIC PCS 7 Hardware Configuration Manual.
  • SIOS Entry 109742323: PCS 7 Compendium Part A - Configuration Guidelines (Section: Field Device Integration).
  • SIOS Entry 109809264: SIMATIC Process Control System PCS 7 Released Modules.
  • Siemens Support FAQ: How to Install a GSD/GSDML File in STEP 7 V5.x.

Related Articles

Related Tags

  • HW Config
  • GSD
  • GSDML
  • SINAMICS G120
  • Hardware Catalog
  • PROFINET
  • Industrial Automation
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