C135 PCS 7 (PCS7)
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Integrating S7-1200 Controllers as PROFINET I-Devices into SIMATIC PCS 7 S7-400H Systems

Integrating S7-1200 Controllers as PROFINET I-Devices into SIMATIC PCS 7 S7-400H Systems

In SIMATIC PCS 7 (V9.0 / V9.1), integrating SIMATIC S7-1200 PLCs into an S7-400H or CPU 410-5H architecture via PROFINET I-Device GSDML files enables basic cyclic peripheral data exchange, but standard PCS 7 channel drivers cannot be used. Compiling CFC charts with 'Generate module drivers' fails because the PCS 7 driver generator does not support S7-1200 I-Devices as standard remote I/O. To resolve this, exchange data between S7-400 and S7-1200 using communication blocks (such as BSEND/BRCV or PUT/GET) or read peripheral words directly via user blocks, and connect the non-redundant S7-1200 via a PN/PN Coupler or Y-Switch for S7-400H network fault tolerance.

Table of Contents

Executive Summary

In industrial manufacturing facilities (such as cement plants, water treatment facilities, and pharmaceutical plants), auxiliary subsystems (e.g., bag filters, chemical injection skids, and local pump skids) are frequently automated using cost-effective SIMATIC S7-1200 basic controllers programmed in TIA Portal. When integrating these standalone skids into a plant-wide SIMATIC PCS 7 control system governed by fault-tolerant S7-400H or CPU 410-5H controllers, system integrators often export an I-Device GSDML file from TIA Portal and import it into PCS 7 HW Config.

While hardware communication appears healthy and online data monitoring in HW Config confirms active peripheral data transfer, compiling CFC charts with 'Generate module drivers' aborts with fatal errors. This occurs because the PCS 7 module driver generator is engineered exclusively for standard ET 200 remote I/O families (such as ET 200M and ET 200SP HA); it has no driver definitions for intelligent S7-1200 I-Devices. This guide outlines the architectural constraints of S7-1200 integration in PCS 7 and provides the correct engineering methods for cyclic and acyclic communication.

Architecture and Fundamental Mechanics

The architectural boundary between SIMATIC PCS 7 and SIMATIC S7-1200 basic controllers enforces distinct communication paradigms:

  1. Non-Technological Nature of S7-1200 in PCS 7:
    - S7-1200 controllers are not native PCS 7 components. They cannot be programmed in CFC, cannot instantiate PCS 7 APL technological blocks, and do not support standard PCS 7 diagnostic interrupts.
    - When an S7-1200 is configured as a PROFINET I-Device, TIA Portal generates a GSDML file describing simple cyclic input/output transfer areas (e.g., 64 bytes IN / 64 bytes OUT).

  2. The CFC Driver Generation Failure:
    - In PCS 7, connecting channel driver blocks (Pcs7DiIn, Pcs7AnIn) to hardware addresses triggers the driver generator (Generate module drivers) to build @ charts and evaluate module diagnostics.
    - Because the S7-1200 GSDML is an I-Device rather than a physical ET 200 interface module, the driver generator finds no matching XML action files in S7DATA\driver\action\ and aborts with 'Driver block for module cannot be generated'.

  3. Redundancy Limitations of S7-1200:
    - S7-1200 controllers feature only standard PROFINET interfaces (single IP/MAC stack); they do NOT support PROFINET system redundancy (S2 redundancy).
    - An S7-1200 cannot connect directly to both CPUs of an S7-400H pair simultaneously without specialized network couplers.

  4. Recommended Integration Pathways:
    - Pathway A: S7 Communication Blocks (BSEND / BRCV or PUT / GET) over Industrial Ethernet, which decouples cyclic I/O and provides robust handshaking.
    - Pathway B: Cyclic I-Device Data via a PN/PN Coupler or raw peripheral addressing in custom CFC blocks, bypassing the automated module driver generator.

Step-by-Step Implementation Procedure

Follow these steps to integrate an S7-1200 controller into PCS 7 without driver compilation errors:

  1. Configure S7-1200 I-Device in TIA Portal:
    - In TIA Portal, open the S7-1200 project.
    - In the PROFINET interface properties, navigate to 'Operating mode' and check 'IO device' (I-Device).
    - Define transfer areas (e.g., Transfer Area 1: 32 bytes Output from S7-1200 to S7-400, 32 bytes Input from S7-400).
    - Click 'Export' to generate the I-Device GSDML XML file.

  2. Install GSDML in SIMATIC Manager HW Config:
    - Open SIMATIC Manager on the PCS 7 Engineering Station.
    - Open HW Config for the S7-400 station.
    - Select 'Options > Install GSD Files...'.
    - Browse to the exported GSDML file and click 'Install'.

  3. Configure S7-1200 Node on PROFINET IO System:
    - In the HW Config hardware catalog, locate the installed GSDML under 'PROFINET IO > Additional Field Devices > PLCs > S7-1200'.
    - Drag the S7-1200 I-Device onto the PROFINET IO network.
    - Assign device name, IP address, and peripheral I/O addresses (e.g., IW 1024 to IW 1054).
    - Select 'Station > Save and Compile'.

  4. Implement Custom Data Access in CFC (Bypassing Module Drivers):
    - Do NOT connect standard APL channel driver blocks (Pcs7AnIn/Pcs7DiIn) to the S7-1200 I-Device addresses!
    - Instead, create a custom communication chart or use elementary conversion blocks (such as Word_To_Bits or custom SCL/LAD blocks) to read peripheral words directly (PIW 1024, PIW 1026).
    - Pass the unpacked signals into standard APL technological blocks (e.g., MonDiL, MonAnL) by connecting to PV_In.Value and setting PV_In.ST = 16#80 (Good).

  5. (Alternative Pathway) Configure S7 Communication Blocks (BSEND / BRCV):
    - In NetPro, configure an S7 Connection between the S7-400 CPU and the S7-1200.
    - In CFC, place block BSEND (SFB12) and BRCV (SFB13) from the Standard Library.
    - Transmit structured process data cyclically without modifying HW Config.

Verification

  1. In HW Config, switch to Online Mode: verify that the S7-1200 PROFINET node reports healthy communication with green checkmarks.
  2. Open the custom CFC chart in Test Mode: confirm that peripheral inputs (PIW) reflect active process measurements from the S7-1200.
  3. Modify a setpoint or command bit in PCS 7: verify that the S7-1200 receives the updated output word in TIA Portal monitoring.
  4. Compile CFC charts with 'Generate module drivers': verify that the compilation completes with 0 Errors.

Limitations and Operational Precautions

Direct I-Device mapping provides no automated hardware diagnostics (such as rack failure, wire break, or module health alarms) within PCS 7; all diagnostic monitoring must be manually programmed. S7-1200 cannot participate in S7-400H bumpless redundancy. S7 controller options and engineering software should be verified through an authorized Siemens distributor or the Siemens Industry Mall.

Engineer FAQ

Why does 'Generate module drivers' fail on an S7-1200 I-Device?

Because the PCS 7 driver generator only supports ET 200 remote I/O families and lacks driver action rules for intelligent S7-1200 I-Devices.

Can S7-1200 be programmed directly inside PCS 7 SIMATIC Manager?

No. S7-1200 controllers must be programmed using TIA Portal (STEP 7 Basic or Professional).

Does S7-1200 support S7-400H S2 system redundancy?

No. S7-1200 controllers do not support PROFINET S2 redundancy natively.

What is the best communication method between S7-400H and S7-1200?

S7 Communication using BSEND/BRCV or open user communication over Industrial Ethernet, or cyclic I/O via a PN/PN Coupler.

Can S7-1200 data be displayed on PCS 7 WinCC faceplates?

Yes, by passing unpacked process signals into standard APL monitoring blocks such as MonAnL and MonDiL.

Technical References

Related Articles

Related Tags

  • S7-1200
  • I-Device
  • GSDML
  • PROFINET
  • Module Drivers
  • PCS 7 V9.0
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