Integrating R. STAHL IS1 Remote I-O Channel Blocks into PCS 7 APL

R. STAHL IS1 and IS1+ intrinsically safe remote I/O channel blocks (DI, DO, AI, AO) are not included in the standard Siemens Advanced Process Library (APL) catalog. To integrate STAHL IS1 modules with full PCS 7 driver generator support and APL-compliant faceplates, acquire the official 'R. STAHL IS1 PCS 7 APL Field Device Library' available through Siemens Function Block Service ([email protected]) or R. STAHL Automation. Alternatively, integrate the IS1 rack using standard GSD files, uncheck 'Generate module drivers' in HW Config, and wire peripheral addresses directly to standard APL channel blocks.

Why R. STAHL IS1 Blocks Are Absent from the Standard APL Catalog

The R. STAHL IS1 and IS1+ remote I/O systems are market-leading solutions for explosion-proof, intrinsically safe field signal concentration in hazardous industrial areas (ATEX Zone 1 / Zone 2, IECEx, and Class I, Div 1 / Div 2). When engineers install SIMATIC PCS 7 V9.0, they discover that the CFC block catalog contains driver blocks for Siemens distributed I/O families (ET 200M, ET 200SP, ET 200iSP), but contains no entries for R. STAHL.

Because R. STAHL is a third-party manufacturer, specialized diagnostic blocks and module driver XML descriptors (MODDRV) cannot be distributed on the standard Siemens PCS 7 media DVD. Attempting to use Siemens ET 200 driver blocks with STAHL hardware causes the driver generator to abort during CFC compilation.

The Certified R. STAHL IS1 PCS 7 APL Field Device Library

To provide seamless, native integration, Siemens and R. STAHL collaboratively developed and maintain the R. STAHL IS1 Field Device Library for SIMATIC PCS 7 (APL):

Library Contents: Includes dedicated driver and diagnostic blocks:
IS1_DI / IS1_DO: Digital input/output channel drivers supporting flutter suppression and pulse counting.
IS1_AI / IS1_AO: Analog input/output channel drivers supporting 4–20 mA HART signal extraction.
IS1_DIAG / IS1_RACK: Communication and rack diagnostic blocks monitoring CPM (Communication Processor Module) health.
Integration Benefits: Fully integrates with the PCS 7 Driver Generator (Generate module drivers). The compiler automatically links hardware diagnostic bytes, evaluates wire breaks, generates WinCC Maintenance Station alarms, and outputs native APL structured tags (Value + ST).
Procurement: Contact the Siemens Function Block Service ([email protected]) or your local R. STAHL distributor.

Alternative Integration Workflow via Standard GSD and APL Drivers

If project timelines do not allow obtaining the certified STAHL APL library, integrate the hardware using standard tools:

Install GSD / GSDML: Import the official R. STAHL GSD file for the IS1 CPM into STEP 7 HW Config.
Disable Module Drivers in HW Config:
- In HW Config, select the STAHL IS1 slave.
- Open Object Properties -> Module Drivers tab.
- Critical Step: Deselect / uncheck Generate module drivers.
Direct Interconnection in CFC:
- Use standard APL channel drivers (Pcs7DiIn, Pcs7DiOu, Pcs7AnIn, Pcs7AnOu).
- Connect the physical I/O address (e.g. IW 512) directly to the PV_In or raw input pin.
- Configure the channel driver input parameter Mode manually (e.g. 16#0201 for 4–20 mA HART) and leave diagnostic pins unconnected.

STAHL IS1 Integration Architecture Comparison Matrix

The following table compares integration pathways for R. STAHL IS1 remote I/O in SIMATIC PCS 7:

Integration ApproachDriver Generation Supported?HART Diagnostics in WinCCMaintenance Station AlarmsSoftware RequirementsCertified R. STAHL APL LibraryYes (Automatic module drivers)Full (Native HART pass-through)Automatic system alarmsSTAHL APL Library PackageStandard GSD (Manual Mapping)No (Must be unchecked)Basic (Cyclic process value only)Manual programming requiredStandard PCS 7 APL (Free)SIMATIC PDM IntegrationN/A (Engineering parameterization)Full device parameterizationOffline asset managementSIMATIC PDM + STAHL EDDSiemens ET 200iSP AlternativeYes (Native Siemens)FullAutomatic system alarmsSiemens ET 200iSP Hardware

[!NOTE]
Commercial Accuracy Notice: The R. STAHL IS1 APL Field Device Library is an optional commercial software package licensed > per plant or per engineering seat. Signal addresses connected to APL channel drivers consume standard PCS 7 AS and OS Process > Objects regardless of which library is utilized.

Verification

Verify that STAHL IS1 signals execute accurately in runtime:

CFC Compilation Status: Execute a full compilation with Generate module drivers enabled. Confirm that compilation concludes with 0 Errors.
Signal Quality and Field Value: Turn on Test Mode in CFC. Confirm that input channels display live process values with Signal Status ST = 16#80 (Good).
Diagnostic Trip Test: Disconnect a field sensor wire. Verify that the channel driver immediately detects the open loop, asserts output Bad = TRUE, changes ST to 16#00, and triggers an operator alarm.

Limitations and Operational Precautions

Observe these guidelines when operating STAHL IS1 I/O:

Redundant CPM Switching: If utilizing redundant IS1 Communication Processor Modules on PROFIBUS DP, ensure the redundancy parameters in HW Config match the physical baud rate and bus profile (flying redundancy).
SIMATIC PDM EDD Alignment: For online instrument parameterization, install the matching R. STAHL EDD in SIMATIC PDM.
Hazardous Area Clearances: Always verify intrinsic safety calculation records (entity parameters) before connecting field transmitters in hazardous zones.

Engineer FAQ

Why can't I find STAHL blocks in my PCS 7 CFC catalog?

Siemens PCS 7 media DVDs only include drivers for Siemens hardware. Third-party field device libraries must be installed separately.

How can I obtain the R. STAHL IS1 PCS 7 APL Library?

Contact Siemens Function Block Service at [email protected] or contact your authorized R. STAHL representative.

Can I use standard Siemens Pcs7AnIn blocks with STAHL IS1 without the library?

Yes, provided you disable 'Generate module drivers' for the STAHL rack in HW Config and wire the input addresses directly.

Does STAHL IS1 support bumpless hot-swapping in Zone 1?

Yes. R. STAHL IS1 and IS1+ modules are intrinsically safe and certified for hot-swapping individual I/O modules directly in Zone 1 without de-energizing the rack.