Integrating SIMOCODE pro V PN Profisafe Modules in PCS 7 and S7 F-Systems

Integrating a SIMOCODE pro V PN motor management system with fail-safe digital inputs/outputs into PCS 7 and S7 F-Systems requires configuring the SIMOCODE pro V PN basic unit (3UF7011-1AB00-0) alongside the fail-safe expansion module (3UF7320-1AB00-0) in HW Config. You cannot connect generic fail-safe output driver F_CH_BO directly to raw hardware addresses like Q3000.0 without generating driver errors. Instead, install the SIMOCODE pro PCS 7 Library, configure the correct F-destination address and Profisafe F-parameters in HW Config, and interconnect fail-safe signals using the certified SIMOCODE pro fail-safe channel driver blocks.

Architecture of SIMOCODE pro V PN Fail-Safe Integration

SIMOCODE pro V PN (3UF7011-1AB00-0) provides comprehensive motor protection, control, and diagnostics over PROFINET IO. By attaching the fail-safe digital expansion module (3UF7320-1AB00-0), the motor starter supports functional safety functions up to SIL 3 / PL e, such as safe emergency stop, safety gate monitoring, and fail-safe motor tripping over Profisafe.

In a SIMATIC PCS 7 environment with S7 F-Systems (running in an S7-400H/F controller 6ES7410-5HX08-0AB0), safety telegrams and standard cyclic data share the same physical PROFINET network. The SIMOCODE system transmits standard motor control telegrams (e.g., Basic Data Type 2) to standard CFC blocks, while safety-related shutdown commands and input feedbacks are encapsulated in Profisafe telegrams exchanged with the F-CPU.

Hardware Selection and Profisafe Submodule Addressing

The following table lists the essential hardware components and configuration parameters required for fail-safe SIMOCODE pro V PN operation:

Component / ParameterOrder Number (MLFB) / PropertyFunction in Hardware ConfigurationSIMOCODE pro V PN Basic Unit3UF7011-1AB00-0PROFINET basic unit managing standard motor control and communications.Fail-Safe Digital Module3UF7320-1AB00-0DM-F Local or DM-F PROFIsafe module executing fail-safe actuator shutdown.Basic Data Type 2HW Config SubmoduleExchanges 4 bytes input / 4 bytes output for standard motor control (Run, Stop, Fault).PROFIsafe SubmoduleHW Config SubmoduleAssigned fail-safe I/O address range (e.g., I3000..3005 / Q3000..3005).F-Destination AddressF-Parameter (F_Dest_Add)Unique safety network identifier matching DIP switches on the fail-safe module.F-Source AddressF-Parameter (F_Source_Add)Central F-CPU safety address defined in controller hardware properties.F-Monitoring TimeF-Parameter (F_WD_Time)Profisafe communication watchdog timer (typically 100 ms to 250 ms).

Table 1: Hardware and configuration parameters for SIMOCODE pro V PN Profisafe integration.

Resolving Driver Generator Compilation Errors with F_CH_BO

A frequent error occurs when an engineer places a standard S7 F-Systems channel driver block—such as F_CH_BO (FB347) or F_CH_DO—in CFC and connects its value input directly to a raw peripheral address (e.g., Q3000.0). When executing Chart > Compile > Generate Module Drivers, compilation halts with the error:
"Module is not configured or there is no interconnection at Value".

This failure occurs because:
1. Module Driver Database Architecture: The PCS 7 Driver Generator requires diagnostic metadata provided by the device's Object Manager (OM) or EDD within the SIMATIC catalog. Generic GSDML files do not contain the PCS 7 diagnostic rules required to generate @F_MOD_DG blocks for third-party Profisafe submodules.
2. Channel Driver Incompatibility: Standard F_CH_BO expects standard ET 200M/ET 200SP fail-safe electronic modules (6ES7326-2BF10-0AB0). For SIMOCODE, you must use the certified channel blocks provided with the SIMOCODE pro PCS 7 Library (3ZS1632-1XX02-0YA0), or utilize the designated S7 F-Systems F-channel driver blocks mapped to symbolic addresses created in the Symbol Table.

Configuring F-Parameters and Safety Communication in S7 F-Systems

To successfully commission the fail-safe interface:

Configure Hardware in HW Config:
* Insert SIMOCODE pro V PN from the PROFINET IO catalog (using the SIMOCODE ES library device rather than generic GSD).
* Insert the Basic Data Type 2 submodule and the PROFIsafe submodule.
* Assign logical addresses (e.g., I3000 and Q3000).
* In the Profisafe tab of module properties, configure F_Dest_Add and set F_WD_Time appropriately.
Define Symbolic Tags:
* Open the STEP 7 Symbol Table.
* Create symbolic names for the fail-safe address pins: SIMO_M01_F_Out at Q3000.0 and SIMO_M01_F_In at I3000.0.
CFC Program Connection:
* In the safety CFC chart, insert the fail-safe driver block from the SIMOCODE library (or F_CH_DO).
* Interconnect the driver's process input to the symbolic tag SIMO_M01_F_Out.
* Interconnect the driver output VALUE to the safety trip logic (e.g., emergency stop or Safety Matrix effect).
Compile and Download:
* Compile CFC charts with Generate Module Drivers enabled.
* Verify that the F-Compiler compiles the safety program and updates the collective signature.

Verification

To confirm proper communication and safety shutdown operation:

In SIMATIC Manager, download the hardware configuration and safety program to the F-CPU.
Check physical LEDs on the SIMOCODE pro V PN and DM-F module: verify that PROFINET link is green and PROFIsafe LED is solid green (indicating active safety communication without bus fault).
In CFC test mode, verify that the fail-safe channel driver output QUALITY indicates 16#80 (Valid).
Execute a safety trip test: trigger the emergency stop condition and verify that the SIMOCODE fail-safe module immediately de-energizes the motor contactor within the configured safety reaction time.

Limitations and Operational Precautions

Never operate SIMOCODE fail-safe modules without validating DIP switch settings against the hardware configuration; mismatched F_Dest_Add values cause Profisafe communication passivations.
Installing and operating SIMOCODE pro in PCS 7 requires the SIMOCODE pro PCS 7 Library (3ZS1632-1XX02-0YA0) and appropriate engineering/runtime licenses. Always validate final software licensing and MLFBs with an authorized Siemens distributor.
Ensure PROFINET network topology and update times comply with safety timing calculations to avoid spurious Profisafe watchdog timeouts.

Engineer FAQ

Can SIMOCODE fail-safe inputs be evaluated directly in standard CFC charts?

No. Profisafe telegram data must be evaluated within certified safety runtime groups by S7 F-Systems blocks. Standard CFC blocks cannot process Profisafe CRC-protected telegrams.

What is the difference between DM-F Local and DM-F PROFIsafe?

DM-F Local performs hardware-wired fail-safe motor tripping locally (e.g., local e-stop) without network communication. DM-F PROFIsafe executes fail-safe commands transmitted across PROFINET from the central F-CPU.

Why did the module driver generator fail on Q3000.0?

Because direct absolute addressing on non-standard Profisafe devices prevents the driver generator from identifying module catalog metadata; assigning a symbolic tag in the Symbol Table resolves the hardware reference.